Motor Stator Sensor Pocket With Direct Winding Thermal Contact
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Solution Overview
Problem
Existing stator designs for electric motors suffer from slow temperature detection due to delayed heat transfer to temperature monitoring elements, leading to inefficient operation and potential winding damage during pocket formation.
Innovation Solution
A stator design with deformable, thermally conductive contact elements that directly abut the windings, forming pockets for temperature sensors during overmolding, ensuring rapid temperature monitoring and minimizing winding damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature monitoring elements are arranged on windings using domes leading out of remolding, then thermal monitoring is achieved, but the reaction time to temperature changes is slow
Solution Approach 1:
A thermally conductive contact element is introduced as an intermediary between the winding and the temperature monitoring element. This contact element is pressed against the winding during overmolding, creating direct thermal contact that rapidly transfers temperature changes to the sensor, eliminating the time delay associated with dome-based monitoring.
2Measurement precision
If pockets are arranged between windings with elements forming the pockets, then temperature monitoring is enabled, but heat transfer to the sensor is slow due to spacing by remolding
Solution Approach 1:
The contact element serves as a thermal intermediary that bridges the gap between the winding and the temperature sensor. By being pressed directly against the winding during overmolding, it ensures efficient heat transfer to the sensor located in the pocket, eliminating the thermal resistance introduced by remolding spacing.
3Ease of manufacture
If cores are guided on windings during overmolding to form pockets, then pocket formation is achieved, but the windings are damaged comparatively easily
Solution Approach 1:
The contact element is pressed against the winding by the overmolding process itself rather than by a core. This eliminates the need for a physical core to be guided on the winding, thereby preventing mechanical damage to the winding while still achieving proper pocket formation and sensor positioning.
4Reliability
If motor is switched off at low temperatures or power reduced to ensure sufficient protection, then motor protection is achieved, but operation efficiency is reduced
Solution Approach 1:
The mechanical dome-based temperature monitoring system is replaced with a direct thermal contact system using the contact element. This provides more accurate and rapid temperature detection, allowing the motor to operate closer to its thermal limits with confidence, thereby improving efficiency while maintaining protection.
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
Enables precise and rapid temperature detection of windings, allowing efficient motor control and preventing damage during pocket formation.
Implementation Method 1
the at least one contact element is formed to be deformable and/or deflectable in the circumferential direction relative to the axis of rotation for direct contact with at least one of the windings... a winding-side wall of the pocket is formed, at least in a section, by the contact element directly abutting the winding
Data Source
AI summary
A stator for an electric motor having stator teeth arranged about an axis of rotation, which are each wound with a winding, and at least one heat-conductive contact element, wherein the at least one contact element extends in the axial direction from a region adjoining the windings in the axial direction in each case between two windings and is formed to be deformable and/or deflectable in the circumferential direction for direct contact with at least one of the windings. The windings are overmolded or remolded with an electrically non-conductive material forming an encapsulation, which material forms with the at least one contact element in each case a pocket for receiving a temperature monitoring element which can be inserted in the axial direction, the winding-side wall of which is formed at least in a section by the contact element directly abutting the winding.