Stator Temperature Sensing via External Heat-Conducting Element
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Solution Overview
Problem
Existing methods for integrating temperature sensors into stators of electrical machines are complex, difficult to automate, and require manual handling of sensor cables, making them inefficient and costly.
Innovation Solution
A stator design with a heat-conducting element outside or protruding from the coil, where the temperature sensor is in direct thermal contact with the heat-conducting element, simplifying assembly and eliminating the need for pre-impregnation attachment, using a sensor holder with a receiving space for precise thermal contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature sensor is integrated into the stator using prior art methods (sensor carrier, guide elements, encapsulation in impregnating resin), then the temperature can be monitored, but the assembly process becomes complex and difficult to automate
Solution Approach 1:
The invention extracts the temperature sensor from the complex assembly process by providing it as a separate component that is inserted into a receiving space in the stator core after impregnation. This eliminates the need for sensor carriers, guide elements, and pre-impregnation attachment, significantly simplifying the assembly process while maintaining reliable temperature monitoring capability
Solution Approach 2:
The stator is divided into functional modules: the stator core with receiving spaces, the impregnated coil assembly, and the temperature sensor as a separate insertable component. This segmentation allows each component to be prepared independently and assembled in a simple sequential process, enabling automation
2Stability of the object's composition
If the temperature sensor is attached before impregnation and encapsulated in impregnating resin, then the sensor is fixed in position, but manual handling and positioning are required
Solution Approach 1:
The receiving spaces are pre-formed in the stator core before impregnation, and the temperature sensors are prepared separately. After impregnation, the sensors are simply inserted into the pre-prepared receiving spaces, eliminating the need for manual positioning and attachment during the impregnation process itself
3Reliability
If the heat-conducting element is arranged inside the coil, then thermal contact with the coil is achieved, but the temperature sensor cannot be easily accessed for assembly
Solution Approach 1:
The heat-conducting element is arranged to extend from the interior of the coil through the coil winding to the exterior, where it protrudes radially outward. This dimensional extension allows the temperature sensor to be attached on the outside of the coil, making assembly easy while maintaining reliable thermal contact through the heat-conducting element
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 enables reliable, automated, and cost-effective temperature measurement of the stator coil, reducing assembly complexity and allowing for precise monitoring of temperature hotspots without the need for manual handling of sensor cables.
Implementation Method 1
the temperature sensor being arranged in direct thermal contact with the heat-conducting element
Data Source
Figure 1~2
Figure 3~4
Figure 5~6c
AI summary
To provide a stator for an electric machine whose assembly is simple and easily automated, which allows reliable temperature measurement and is cost-effective to manufacture, a stator (100) for an electric machine is proposed, comprising a coil (10) with a coil winding or a hairpin winding and a temperature sensor (17), wherein the stator has a heat conducting element (24), wherein the temperature sensor (17) is arranged in direct or indirect thermal contact with the heat conducting element (24), and wherein the heat conducting element (24) is arranged outside the coil (10) and/or protrudes from the coil (10).