Stator Temperature Sensor Mounting via Switching Disk Inversion
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Solution Overview
Problem
The existing stator designs for electric motors are complex and difficult to assemble, particularly when integrating a temperature monitor, as they often require intricate wiring arrangements and multiple parts, leading to inefficient heat transfer and increased manufacturing costs.
Innovation Solution
The temperature monitor is mounted from the top side of the switching disk through a through-opening, with a spring element providing a pressing force for contact with the stator winding, and can be easily inserted and secured after the switching disk is installed, using a separate or integrated receiving part for improved thermal conductivity and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature monitor is inserted from the underside of the switching disk before installation, then the temperature monitor can be fixed with connecting wires clamped by fixing elements, but the assembly process becomes complex and time-consuming
Solution Approach 1:
Instead of inserting the temperature monitor from the underside of the switching disk before installation, the invention inverts the approach by inserting the temperature monitor from the top side after the switching disk is installed. The temperature monitor is inserted through a through-opening in the switching disk, and the spring element is attached to the underside to provide pressing force against the stator winding. This inversion simplifies the assembly process while maintaining reliable fixation.
Solution Approach 2:
The invention merges the temperature monitor insertion process with the switching disk installation process. By providing a through-opening in the switching disk that accommodates the temperature monitor, both components can be integrated in a single assembly step rather than requiring separate operations for temperature monitor insertion and switching disk installation.
2Reliability
If multiple separate components are used for temperature monitor mounting, then the temperature monitor can be securely fixed, but the number of components increases and manufacturing costs rise
Solution Approach 1:
The invention combines the temperature monitor mounting function with the switching disk structure itself. The through-opening in the switching disk serves as both a structural feature and a mounting mechanism for the temperature monitor. The spring element, while separate, is simplified in design and attaches directly to the switching disk underside, reducing the need for additional mounting brackets, screws, or complex fixation mechanisms.
Solution Approach 2:
The switching disk is designed with multi-functionality: it serves as an electrical switching component, a structural support element, and a mounting mechanism for the temperature monitor. The through-opening in the switching disk simultaneously accommodates the temperature monitor and provides attachment points for the spring element, eliminating the need for dedicated mounting structures.
3Ease of manufacture
If the temperature monitor is indirectly exposed to stator winding heat, then the assembly is simpler, but heat transfer efficiency is reduced
Solution Approach 1:
Instead of positioning the temperature monitor to be indirectly exposed to heat through a recess or barrier, the invention inverts the approach by having the temperature monitor directly contact the stator winding. The temperature monitor is inserted through a through-opening in the switching disk and pressed directly against the stator winding by a spring element, ensuring optimal thermal contact while allowing simple assembly.
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 configuration simplifies the assembly process, enhances heat transfer by ensuring direct contact between the temperature monitor and the stator winding, and reduces the number of components needed, thereby lowering manufacturing costs and complexity.
Implementation Method 1
the temperature monitor is acted upon by a spring-elastic pressure force, for which purpose the switching disk has a spring arm that generates the pressure force in the region of the temperature monitor
Implementation Method 2
the temperature monitor then lies on the end winding in heat-conducting contact with the stator winding between the stator winding and the switching disc
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The invention relates to a stator (1) for an electric motor, particularly for an external rotor motor, having a stator sheet stack (2) provided with a stator winding (8) and having an interconnection arrangement (20) arranged on a face in the region of an end winding (9) of a stator winding (8) for electrically connecting winding wire ends of the stator winding (8) and connection wires (16) of a temperature controller (18) connected upstream of the stator winding (8). The interconnection arrangement (20) comprises an isolated switching disk (22) overlapping the region of the end winding (9), particularly in the form of a cap. The temperature controller (18) is kept integrated in the switching disk (22) such that it sits at the end winding side between the stator winding (8) and the switching disk (22) in a heat conducting contact with the stator winding (8).