Stator Jumper Wire Support Assembly
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Solution Overview
Problem
Existing electric machine stator assemblies experience stress in weld joints due to unsecured electrical jumper wires, leading to potential mechanical failure and reduced efficiency.
Innovation Solution
A connection support assembly is introduced, comprising a support body with a catch and a clip that clamps electrical jumper wires between the support body and the clip, minimizing stress on weld joints by securing the wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrical jumper wires are left unsecured, then the device complexity is reduced, but stress in weld joints increases leading to potential mechanical failure
Solution Approach 1:
A support assembly acts as an intermediary component between the electrical jumper wires and the stator assembly. The support assembly includes a support body with a recess that receives the jumper wires, and a clip that secures the wires within the recess. This intermediary structure distributes mechanical stress away from the weld joints, preventing stress concentration while maintaining electrical connectivity.
Solution Approach 2:
The support assembly is segmented into distinct functional components: a support body that provides the structural framework, a recess that cradles the jumper wires, and a clip that applies securing force. This segmentation allows each component to perform its specific function optimally - the recess protects the wires from stress, while the clip provides secure attachment without requiring complex integration.
2Reliability
If electrical jumper wires are secured with a support assembly, then stress in weld joints is minimized, but device complexity increases
Solution Approach 1:
The support assembly is designed to be self-contained and self-securing. The clip engages with the support body through a simple insertion mechanism where the clip's resilient arms snap into place within the recess, providing automatic retention without requiring additional fasteners, adhesives, or complex assembly steps. This self-service design minimizes the increase in device complexity while achieving reliable wire securing.
3Strength
If electrical jumper wires are clamped between support body and clip, then mechanical integrity is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The support body features a recess with specific dimensional parameters - a width that accommodates the jumper wires with clearance, and a depth that allows the clip to apply securing force without excessive compression. The clip's resilient arms are designed with specific elasticity parameters that provide sufficient clamping force while accommodating normal variations in wire diameter and positioning, reducing the impact of manufacturing tolerances.
Data Source
AI summary
A connection support assembly for a stator assembly can be used to secure electrical jumper wires of an electric machine. The connection support assembly includes a support body and a catch protruding from the support body. The catch defines an opening. The connection support assembly further includes a clip coupled to the support body. The clip includes a clip body and a pin protruding from the clip body. The pin extends through the opening of the catch in order to couple the clip to the support body and clamp at least some electrical jumper wires between the support body and the clip.