Electric Motor Stator Sensor Mounting With Busbar Hole Nesting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing structures for attaching temperature sensors to stators in electric motors result in increased size and resin usage due to the conductive member being bent to hold the sensor, thereby thickening the attachment portion.
Innovation Solution
A stator design where the temperature sensor is inserted into a hole in the conductive member, reducing the thickness of the resin-covered portion and minimizing resin usage, while ensuring the sensor is securely attached and in close contact with the neutral busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductive member is bent to hold the temperature sensor, then the temperature sensor can be securely attached, but the thickness of the attachment portion increases, resulting in increased size and increased amount of resin required
Solution Approach 1:
The temperature sensor is inserted into a hole formed in the conductive member, nesting the sensor within the conductive member's structure. This eliminates the need to bend the conductive member outward to hold the sensor, thereby maintaining secure attachment while reducing the overall thickness and volume of the attachment portion.
2Reliability
If the conductive member is bent to hold the temperature sensor, then the temperature sensor can be securely attached, but the thickness of the attachment portion increases, resulting in increased amount of resin required
Solution Approach 1:
By nesting the temperature sensor inside the conductive member's hole, the external dimensions of the attachment portion are reduced. This directly decreases the volume of resin needed to cover and insulate the attachment area, thereby reducing the quantity of resin material required.
3Volume of moving object
If the temperature sensor is inserted in the hole of the conductive member, then the resin amount and stator size are reduced, but the temperature sensor must be securely fixed in the hole
Solution Approach 1:
The hole in the conductive member is designed with specific dimensional parameters (diameter slightly smaller than the temperature sensor's outer diameter) to create an interference fit. This parameter change enables the temperature sensor to be securely fixed in the hole through friction and mechanical engagement, ensuring positioning stability while maintaining the compact design.
Solution Approach 2:
The temperature sensor and hole are designed with circular cross-sections that match each other, enabling smooth insertion and uniform contact around the circumference. This geometric compatibility ensures reliable fixing while maintaining the compact structure.
4Volume of moving object
If the temperature sensor is inserted in the hole of the conductive member, then the resin amount and stator size are reduced, but close contact between the sensor and neutral busbar must be ensured
Solution Approach 1:
The temperature sensor is nested within the conductive member's hole, positioning it in close proximity to the neutral busbar. This nested arrangement ensures thermal contact between the sensor and the busbar while maintaining the compact overall structure, thereby preserving temperature detection accuracy.
Solution Approach 2:
The hole's dimensional parameters are optimized to position the temperature sensor at the optimal distance from the neutral busbar. This parameter optimization ensures sufficient thermal contact for accurate temperature measurement while maintaining the reduced size benefits of the nested design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces the amount of resin required and minimizes the stator's size, while improving the temperature followability of the sensor and enhancing the cooling performance of the stator coils.
Implementation Method 1
the at least the portion of the temperature sensor is interference-fitted in the hole
Implementation Method 2
a resin portion provided to cover at least a part of the conductive member and at least a part of the temperature sensor
Implementation Method 3
improving the temperature followability of the sensor
Data Source
AI summary
A stator for an electric motor includes: (a) a tubular stator core having slots provided through the stator core in a direction of a rotation axis of the stator core; (b) coils inserted through the slots; (c) a conductive member electrically connected to the coils; (d) a temperature sensor attached to the conductive member; and (e) a resin portion provided to cover at least a part of the conductive member and at least a part of the temperature sensor. The conductive member is provided with a hole that extends in the direction of the rotation axis of the stator core. The temperature sensor is inserted, at least its portion, in the hole.