Stator Connection Unit With Parallel Contacts for Star Point Assembly
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Solution Overview
Problem
Existing connection units for stator windings with multiple phases face difficulties in arranging connection portions due to radial orientation and production-related positional tolerances, making it challenging to form a star point and requiring additional tools for precise positioning.
Innovation Solution
A connection unit with contact portions oriented parallel to each other, allowing for linear movement to facilitate the arrangement of connection portions into receiving chambers, which can compensate for positional tolerances without additional tools, and featuring a conductor arrangement that either connects or isolates contact portions for easy assembly and fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If connection portions are oriented radially corresponding to the substantially cylindrical design of the stator, then the design conforms to the cylindrical stator structure, but it becomes difficult to arrange the connection portions in the receiving chambers due to production-related positional tolerances
Solution Approach 1:
Instead of orienting the receiving chambers radially to match the cylindrical stator structure, the invention inverts the approach by orienting the receiving chambers parallel to one another. This allows the connection portions to be arranged in a linear fashion, making it much easier to accommodate production tolerances while still achieving proper electrical connection.
Solution Approach 2:
The invention changes the orientation parameter of the receiving chambers from radial (matching cylindrical geometry) to parallel (linear arrangement). This parameter change transforms the arrangement from a complex radial positioning task into a simpler linear alignment task that is more tolerant of manufacturing variations.
2Manufacturing precision
If additional tools are used to hold the connection portions in a predefined position, then positioning precision can be achieved, but the device complexity and ease of manufacture are reduced
Solution Approach 1:
The connection unit is designed to self-align and self-position through its parallel receiving chamber configuration. The linear arrangement of receiving chambers naturally guides the connection portions into place without requiring external positioning tools, making the system self-sufficient and reducing overall complexity.
Solution Approach 2:
The parallel orientation of receiving chambers is designed in advance to compensate for expected positional tolerances. This beforehand cushioning approach built into the geometry allows for natural alignment without requiring additional positioning mechanisms or tools during assembly.
3Stability of the object's composition
If the connection portions are arranged radially, then the star point formation follows the cylindrical symmetry, but the mounting process becomes more complex and time-consuming
Solution Approach 1:
The invention segments the connection process by providing individual parallel receiving chambers for each phase connection portion. This segmentation allows each connection to be independently and quickly positioned without requiring complex coordinated positioning of multiple radial elements, thereby increasing mounting productivity.
Data Source
AI summary
Connection unit for a stator having a stator winding with N number of phases. The connection unit includes a number N of contact portions each having a first wall and a second wall, and each contact portion forming a receiving chamber delimited by the first wall and the second wall and designed to encase one of N connection portions of the stator. Each contact portion is configured to electrically contact the connection portion, wherein the first and second walls of the N contact portions are oriented parallel to one other. A conductor arrangement which either electrically conductively connects the contact portions or includes N conductor portions which are electrically isolated from one another and are each electrically conductively connected to one of the N contact portions.