Stator Coil-End Sensor Mounting for Easier Assembly
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Solution Overview
Problem
The assemblability of stators in rotary electric machines is not optimal, particularly in integrating temperature sensors and their holders.
Innovation Solution
A stator design featuring an annular stator core with a slot conductor, coil end conductor, temperature detector, and an attachment member that includes a base portion, biasing portions, and connection portions to securely attach the temperature detector, ensuring proper alignment and preventing detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature sensor holder is used to sandwich the temperature sensor and stator winding portion, then the temperature detector can be fixed to the coil end conductor, but the assemblability is not optimal
Solution Approach 1:
The attachment member is divided into distinct functional segments: a base portion for mounting the temperature detector, a first biasing portion for securing the temperature detector, a second biasing portion for securing the coil end conductor, and connection portions linking these components. This segmentation allows each part to perform its specific function independently, improving both attachment reliability and ease of assembly.
Solution Approach 2:
The biasing portions are designed to be deformable in directions other than the sandwiching direction, allowing them to flex and adapt during assembly. This dynamic characteristic enables the attachment member to accommodate variations in component dimensions and assembly tolerances, significantly improving assemblability while maintaining secure attachment.
2Reliability
If the attachment member is rigid and precisely fitted, then the temperature detector is securely fixed, but the manufacturing cost increases due to precise force adjustments
Solution Approach 1:
The attachment member utilizes elastic deformation characteristics of the biasing portions, changing the mechanical parameter from rigid fixed positioning to flexible elastic positioning. This allows the attachment to maintain security through elastic recovery force rather than requiring precise rigid fitting, thereby reducing manufacturing complexity and cost.
Solution Approach 2:
The biasing portions automatically adjust and secure the temperature detector and coil end conductor through their elastic deformation and recovery, without requiring external force adjustment mechanisms or complex assembly procedures. This self-service characteristic reduces manufacturing cost by eliminating the need for precise force adjustments.
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
Enhances the assemblability of the stator by ensuring secure attachment of the temperature detector without requiring precise force adjustments, improving measurement accuracy and reducing manufacturing costs.
Implementation Method 1
a first biasing portion that biases the temperature detector to the base portion side
Implementation Method 2
a second biasing portion that biases the coil end conductor to the base portion side
Data Source
AI summary
A stator of a rotary electric machine includes an annular stator core having a slot, a slot conductor disposed in the slot, a coil end conductor that is disposed outside the slot and connected to the slot conductor, a temperature detector attached to the coil end conductor, and an attachment member that fixes the temperature detector to the coil end conductor. The attachment member includes a base portion that forms a mounting region in which the temperature detector is disposed, a first biasing portion that biases the temperature detector to the base portion side, a first connection portion that connects one end of the base portion and the first biasing portion, a second biasing portion that biases the coil end conductor to the base portion side, and a second connection portion that connects the other end of the base portion and the second biasing portion.