Stator Switch Disc for External Rotor Motor
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Solution Overview
Problem
Existing stator arrangements for electric motors face challenges such as time-consuming soldering or welding processes, limited flexibility in connection configurations, and increased complexity due to direct wiring and hardwired connections, which complicate manufacturing and assembly.
Innovation Solution
The integration of insulation displacement contacts within a plastic extrusion coating on the stator, combined with a switching disk featuring radial conductor tracks and perforations, allows for pre-assembly and automated winding and testing, enabling plug-and-snap connections that simplify the manufacturing process and reduce component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or welding is used to connect winding wire ends to terminal lugs, then reliable electrical connection is achieved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent replaces thermal joining processes (soldering/welding) with a mechanical insulation displacement connection system. Contact elements with contact sections are inserted into conductor tracks, creating electrical connection through mechanical displacement of insulation material rather than thermal bonding, thereby eliminating heat-affected zones and reducing manufacturing cycle time while maintaining connection reliability
Solution Approach 2:
The patent introduces an intermediary connection system consisting of contact elements and conductor tracks that bridge the winding wire ends and terminal lugs. This intermediate mechanical-electrical connection system eliminates the need for direct thermal joining while ensuring reliable electrical continuity through the insulated conductor track pathway
2Productivity
If direct wiring with insulation displacement contacts is used, then manufacturing time is reduced, but flexibility in connection configuration is limited
Solution Approach 1:
The patent segments the connection system into modular components: conductor tracks with integrated contact elements, switchable connection elements, and selectable connection configurations (series, parallel, delta, star). This segmentation allows flexible reconfiguration of winding connections by simply changing the switchable elements rather than redesigning the entire connection system, maintaining adaptability while preserving manufacturing efficiency
Solution Approach 2:
The patent implements dynamic reconfigurability through switchable connection elements that can be selectively activated or deactivated based on the desired connection type. This dynamic switching capability allows the same physical infrastructure to adapt to different motor winding configurations (series, parallel, delta, star) without requiring physical rewire, thus maintaining flexibility while preserving the time-efficient insulation displacement method
3Ease of operation
If flat plug connections are used for stator contacts, then plug-in capability is achieved, but product complexity increases
Solution Approach 1:
The patent merges the conductor track function with the contact element function into a single integrated component. The conductor tracks have contact sections that directly receive and electrically connect to the contact elements through insulation displacement, eliminating the need for separate flat plug connectors. This integration maintains plug-in capability while significantly reducing the number of discrete components and assembly steps
4Reliability
If hardwired connections through routing cables are used, then stable electrical connection is achieved, but adaptability to different connection types is reduced
Solution Approach 1:
The patent implements dynamic reconfigurability through switchable connection elements that can be selectively activated or deactivated based on the desired connection type. This dynamic switching capability allows the same physical infrastructure to adapt to different motor winding configurations (series, parallel, delta, star) without requiring physical rewire, thus maintaining flexibility while preserving the time-efficient insulation displacement method
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 solution streamlines the manufacturing and assembly of electric motors by eliminating the need for soldering or welding, offering increased flexibility and reducing production time and costs through automated processes and preconfigured assemblies.
Implementation Method 1
a direct electrical connection between the winding wires and the connection line is produced by means of a plugging and joining operation of a receiving housing on the insulating element by means of the insulation displacement effect of the insulation displacement contacts
Data Source
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AI summary
The present invention relates to a stator arrangement for an electric motor, particularly an external rotor motor (1), comprised of a stator (6) having stator windings (8) and a switch disc (10), having conductor tracks (12), which is disposed perpendicular to the motor axis at the stator (6). These contact the winding ends (24) of the stator winding (8), and can be connected to a connecting line (65). Cutting/clamping contacts (22) connect the winding ends (24) of the stator windings (8) to the contact sections of the conductor tracks (12) disposed on the switch disc (10) on the winding side. Further, the present invention comprises a switch disc (10) for an electric motor having a stator (6) and stator windings (8), as well as a stator (6) for the electric motor, particularly for an external rotor motor (1).