Stator Winding Temperature Sensor Clip for Reliable Thermal Coupling
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Solution Overview
Problem
Existing methods for creating a thermally conductive coupling between a temperature sensor and a stator winding in electric machines are cumbersome, difficult to reproduce, and challenging to maintain, particularly in terms of correct adhesive application and sensor replacement without damaging the stator winding insulation.
Innovation Solution
A fastening clip with a latching connection is used to create a thermally conductive coupling between the temperature sensor and the stator winding or a heat-conducting element, allowing for quick and reliable assembly and easy replacement of the temperature sensor without risking damage to the stator winding insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding is used to couple the temperature sensor to the stator winding, then thermal coupling is achieved, but the process becomes cumbersome and difficult to reproduce
Solution Approach 1:
The patent replaces the chemical adhesive bonding system with a mechanical fastening clip system. The clip mechanically secures the temperature sensor to the stator winding or heat-conducting element, eliminating the need for adhesive application, curing time, and complex positioning processes. This mechanical substitution directly resolves the contradiction by improving ease of manufacture while maintaining reliable thermal coupling through direct contact.
Solution Approach 2:
The fastening clip acts as an intermediary component between the temperature sensor and the stator winding/heat-conducting element. It provides a standardized mechanical interface that ensures consistent thermal contact without requiring direct adhesive bonding between the sensor and winding, thereby improving process reliability and ease of manufacture.
2Reliability
If adhesive bonding is used to couple the temperature sensor to the stator winding, then thermal coupling is achieved, but the mounting time increases
Solution Approach 1:
The mechanical fastening clip eliminates the time-consuming adhesive application and curing processes. The clip can be quickly installed and removed without waiting for chemical bonding, directly reducing mounting time while maintaining reliable thermal coupling through consistent mechanical contact.
Solution Approach 2:
The fastening clip is pre-formed with the necessary geometry to secure the temperature sensor and ensure thermal contact. This preliminary preparation eliminates the need for on-site adhesive application and curing, significantly reducing mounting time while ensuring reliable coupling from the moment of installation.
3Reliability
If adhesive bonding is used to couple the temperature sensor to the stator winding, then thermal coupling is achieved, but the temperature sensor cannot be easily replaced
Solution Approach 1:
The mechanical fastening clip system replaces the permanent adhesive bond with a reversible mechanical connection. The temperature sensor can be easily removed by releasing the clip and reinstalled by securing it again, enabling simple replacement without damaging the stator winding insulation. This directly resolves the contradiction by improving ease of repair while maintaining reliable thermal coupling during operation.
Solution Approach 2:
The fastening clip provides a dynamic, reversible connection that transitions from a secure locked state during operation to a released state for replacement. This dynamic capability allows the temperature sensor to be easily replaced when needed, contrasting with the permanent adhesive bond that requires destructive removal.
4Reliability
If adhesive bonding is used to couple the temperature sensor to the stator winding, then thermal coupling is achieved, but the risk of damaging stator winding insulation increases
Solution Approach 1:
The mechanical fastening clip eliminates the need for adhesive application near the stator winding, removing the risk of adhesive contamination or improper application that could damage the insulation. The clip provides a safe mechanical interface that secures the temperature sensor without introducing harmful chemical substances or requiring complex positioning that could compromise insulation integrity.
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
The proposed solution enables a quick and reliable establishment of a thermally conductive coupling between the temperature sensor and the stator winding, facilitating easy replacement of the sensor and ensuring process reliability while minimizing the risk of damaging the stator winding insulation.
Implementation Method 1
the fastening clip presses the temperature sensor against the stator winding or a heat-conducting element thermally conductively connected to the stator winding
Data Source
AI summary
An electric machine includes a stator, which has a stator laminated core and a stator winding arranged in the stator laminated core. In addition, the electric machine includes a temperature sensor, which is thermally conductively coupled to the stator winding and is configured to measure a temperature of the stator winding. The thermally conductive coupling is created by a fastening clip with a latching connection, wherein the fastening clip presses the temperature sensor against the stator winding or a heat-conducting element thermally conductively connected to the stator winding. The invention furthermore specifies a vehicle having such an electric machine, and also a method for producing a thermally conductive coupling between a temperature sensor and a stator winding or a heat-conducting element of an electric machine, the heat-conducting element being thermally conductively connected to the stator winding.