Stator Plug-in Elements with Bent Sections for Space Reduction
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Solution Overview
Problem
Stator designs for electrical machines require additional installation space due to the need for reversing connectors, which cannot be compressed like winding heads, leading to increased space requirements.
Innovation Solution
A stator arrangement with cylindrical slots for plug-in elements featuring a first and third section in a plane and a second section partially bent out of the plane, allowing for reduced overhang dimensions and interlocking elements to minimize space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If reversing connectors are bent into the inner diameter of the stator, then the height of the sub-product is reduced, but the installation space requirement increases
Solution Approach 1:
The plug-in element transitions from a planar configuration to a three-dimensional structure by bending the second section out of the plane defined by the first and third sections. This spatial transformation allows the connector to achieve compact height while maintaining adequate installation space through optimized 3D geometry rather than simply compressing the planar layout.
Solution Approach 2:
The plug-in element is designed to be inserted into slots within the stator body, nesting the connector within the existing stator structure. This nesting approach allows the reversing connector to be integrated into the stator's internal space without requiring additional external installation space.
2Volume of moving object
If plug-in elements are designed with 3D shaping, then the dimensions of the winding head are reduced, but the manufacturing complexity increases
Solution Approach 1:
The plug-in element is divided into three distinct sections (first section, second section, third section) with specific geometric characteristics. This segmentation allows each section to be optimized independently for its function while simplifying the overall manufacturing process through modular design rather than requiring complex monolithic shaping.
Solution Approach 2:
The plug-in element incorporates curved geometries, particularly in the second section which is bent out of the plane, creating a U-shaped or curved configuration. These controlled curvatures reduce the bounding box dimensions of the winding head while being manufacturable through standard bending and forming processes rather than requiring complex 3D shaping.
Data Source
Figure 1~3
Figure 4~6
Figure 7
AI summary
The present invention relates to a stator arrangement (15) for an electric machine with a cylindrical stator body (16), wherein the stator body (16) has adjacent slots into which plug-in elements (1, 2, 3) for current reversal are inserted, wherein the plug-in elements (1, 2, 3) have a first section (5) with a first end, a second U-shaped section (6) and a third section (10) with a second end, wherein the second section (6) is arranged between the first section (5) and the third section (10), and wherein the first section (5) and the third section (10) extend in a plane and the second section (6) is at least partially bent out of the plane.