Stator Winding Interconnection Assembly for Electric Motors
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Solution Overview
Problem
Existing stator designs for electric motors, particularly external rotor motors, face challenges in manufacturing complexity, high part variety, and space inefficiency due to separate winding contact elements and conductor bridges, which increase production costs and complicate the winding process.
Innovation Solution
The integration of winding contact elements and conductor bridges into a single, ring-shaped interconnection element, where (n-1) conductor bridges form a circular connection between n winding contact elements, simplifying production and reducing part count, allowing for a compact design and continuous winding without the need for insulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If winding contact elements and conductor bridges are designed as separate parts, then assembly flexibility is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate components (winding contact elements and conductor bridges) into a single integrated interconnection element. This stamping part features a ring-shaped structure with multiple contact elements radially distributed and connected by conductor bridges, reducing the number of parts while maintaining assembly flexibility through the modular ring design that can be produced in various configurations.
2Ease of operation
If conductor bridges are arranged radially outwards, then winding contact is simplified, but radial space requirement increases
Solution Approach 1:
The patent implements a nested arrangement where interconnection elements are positioned within the stator tooth structure. The contact elements extend radially outwards to contact windings on stator teeth, while the conductor bridges are routed through the stator core interior, nesting the electrical connection path within the existing motor structure and minimizing radial space occupation.
3Reliability
If insulating intermediate layers are used between conductor bridges, then electrical insulation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs conductor bridges made from the same conductive material as the contact elements, creating a homogeneous structure. Electrical insulation between adjacent conductor bridges is achieved through the natural insulation provided by the stator core laminations and slot structures, eliminating the need for additional insulating intermediate layers and simplifying manufacturing to a single-stamping process.
Data Source
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AI summary
The stator has a single- or multi-stranded stator winding that is formed from a set of stator coils (a-l), and a wiring arrangement that is attached at a front side of the stator. The arrangement comprises winding contact units (42) assigned to each strand of the stator winding and are connected over conducting bridges (44). The contact units and the bridges form single-piece wiring units in the form of ring segments. The wiring units are arranged axially parallel at the front side of the stator, where the diameter of all wiring units are same and the height of the bridges are same.