Stator Plastic Sheathing for Compact Electrical Machine Electronics
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Solution Overview
Problem
Electrical machines, particularly those used in motor vehicles, face challenges in accommodating larger electronic components within limited space due to high power demands, leading to inefficiencies in cooling and assembly processes.
Innovation Solution
The design incorporates a plastic sheathing around the stator that houses electronic components and a rotor, allowing for compact arrangement and integration of electronic components within the stator's recess, embedding bearings and electrical connections within the plastic sheathing for enhanced assembly and protection, and utilizing flow grooves for improved cooling and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If larger electronic components are used to meet increasing power demands, then the power output of the electrical machine is improved, but the space required for arrangement increases, which conflicts with the limited space available in motor vehicles
Solution Approach 1:
The patent embeds electronic components directly into the plastic sheathing of the stator, nesting them within the existing structural space rather than requiring separate mounting areas. This allows larger electronic components to be accommodated without increasing the overall volume of the electrical machine, resolving the contradiction between power output and space requirements.
Solution Approach 2:
The patent utilizes the third dimension by creating recesses in the plastic sheathing that extend radially inward, allowing electronic components to be arranged in a radial direction rather than only axially. This dimensional change enables more efficient space utilization and accommodates larger components within the same external dimensions.
2Ease of operation
If electronic components are arranged outside the stator, then assembly and cooling are simplified, but the overall dimensions of the electrical machine increase, reducing compactness
Solution Approach 1:
The patent merges the housing function of the stator with the mounting function for electronic components by integrating them into a single plastic sheathing structure. This combining of functions eliminates the need for separate mounting brackets or housings, maintaining compactness while still allowing accessible arrangement of electronic components for assembly and cooling purposes.
Solution Approach 2:
The plastic sheathing serves multiple functions simultaneously: it provides structural support for the stator, acts as a housing for electronic components, provides cooling channels, and serves as a mounting structure. This multi-functionality eliminates the need for additional separate components, maintaining compact dimensions while facilitating assembly and cooling operations.
3Reliability
If bearings are provided as separately mounted components, then reliability is improved through dedicated bearing support, but manufacturing complexity and assembly costs increase
Solution Approach 1:
The patent combines the bearing support function with the plastic sheathing by embedding bearings directly into recesses formed in the sheathing material. This merging eliminates the need for separate bearing housings, mounting operations, and additional fastening components, thereby reducing manufacturing complexity and assembly costs while maintaining reliable bearing support through the integrated structure.
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 results in a more powerful and compact electrical machine with reduced manufacturing costs, improved assembly efficiency, and enhanced reliability through precise alignment and protection of components.
Implementation Method 1
forming an annular gap that is confined between the rotor and the stator and through which a cooling liquid can flow
Data Source
AI summary
An electrical machine is disclosed. The electrical machine includes a rotor rotatable around an axis of rotation and a stator fixed against rotation with respect to the rotor and which concentrically encloses the rotor, forming an annular gap bounded radially between the rotor and the stator and through which a cooling liquid can flow. The stator is at least partially encapsulated by injection molding with a plastic sheathing. A printed circuit board with electronic components arranged on it and a central opening through which a rotor shaft of the rotor protrudes. The plastic sheathing has on a side facing the printed circuit board at least one recess in which at least one electronic component of the printed circuit board engages.