Stator Self-Supporting Interconnects Reduce Assembly Complexity
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Solution Overview
Problem
The complexity of producing a stator for electric machines is high due to the numerous assembly steps and connection processes required for interconnecting elements, which increases production time and complexity, and can lead to reduced service life and efficiency.
Innovation Solution
A stator design featuring a stator core with grooves for dimensionally stable conductors and self-supporting mechanical connections between interconnecting elements and conductors, eliminating the need for additional carrier elements and assembly processes, and using insulation materials for electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carrier systems and additional assembly steps are used to attach interconnecting elements to the stator, then the interconnecting elements can be securely attached and electrically insulated, but the complexity of the electric machine increases and production becomes less efficient
Solution Approach 1:
The patent combines the mechanical attachment function and electrical insulation function into a single integrated stator structure. The interconnecting elements are directly embedded in the stator core with insulation provided by the stator material itself, eliminating the need for separate carrier systems and reducing overall device complexity while maintaining secure attachment and electrical insulation.
Solution Approach 2:
The patent extracts and eliminates the unnecessary carrier system from the traditional stator assembly. By directly integrating the interconnecting elements into the stator core, the design removes redundant components and simplifies the overall structure while preserving the essential functions of mechanical support and electrical insulation.
2Reliability
If a large number of assembly steps and connection processes are used to attach interconnecting elements, then the interconnecting elements can be properly connected to electrical conductors, but production time increases and productivity decreases
Solution Approach 1:
The patent applies preliminary action by pre-integrating the interconnecting elements directly into the stator core during stator manufacturing. This eliminates the need for subsequent assembly steps to attach carrier systems and connect interconnecting elements, significantly reducing production time and improving productivity while ensuring proper electrical connections are maintained.
Solution Approach 2:
The patent merges the stator manufacturing process with the interconnecting element integration process. By combining these operations into a single manufacturing flow, the design eliminates multiple separate assembly steps and connection processes, thereby reducing production time and increasing manufacturing efficiency.
3Strength
If carrier systems are used to fasten interconnecting elements, then the interconnecting elements can be securely fastened, but the number of components increases and the stator construction becomes more complex
Solution Approach 1:
The patent merges the fastening function into the stator core structure itself. The interconnecting elements are directly embedded in the stator, with the stator material providing both mechanical support and secure fastening. This integration eliminates the need for separate carrier systems and reduces construction complexity while maintaining secure attachment.
Solution Approach 2:
The patent extracts and removes the carrier system from the stator construction. By directly integrating interconnecting elements into the stator core, the design eliminates redundant fastening components and simplifies the overall construction while preserving the secure fastening function through the stator material itself.
Data Source
AI summary
A stator for an electric machine comprises a stator core, at least two grooves which are arranged in the stator core, an electrical winding which comprises at least two dimensionally stable electrical conductors, and at least one interconnecting element on at least one side of the stator core, wherein at least one of the conductors is arranged in the grooves, respectively, the interconnecting element is electrically connected to at least one of the conductors, the interconnecting element is mechanically connected to the stator core via at least one of the conductors, the conductors are each mechanically fixed in the grooves, and the mechanical connection between the interconnecting element and the stator core is self-supporting via at least one of the conductors. In addition, an electric machine and a method for producing a stator for an electric machine are specified.