Sheet-Metal Stator Winding Loops for Compact Motor Connections
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Solution Overview
Problem
In small electric motors, the limited installation space on the insulating end disc of a full metal stator makes it challenging to accommodate terminating domes and contacting devices, which are typically smaller and have lower mechanical strength due to space constraints.
Innovation Solution
A method for forming a stator winding where the winding wire is guided away from the stator lamination stack to form a U-shaped loop, allowing for a compact design without the need for attaching elements to the insulating end disc, and using auxiliary loops and a contacting ring for secure connection to motor electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminating domes and contacting devices are arranged on the insulating end disc, then electrical connections can be established, but the mechanical strength decreases due to smaller size caused by space constraints
Solution Approach 1:
The patent extracts the connection function from the insulating end disc by routing the winding wire directly to the housing. The winding wire is guided through a guide element in the housing and connected to motor electronics outside the stator assembly, eliminating the need for terminating domes and contacting devices on the insulating end disc. This resolves the contradiction by removing the space-constrained components while maintaining electrical connection capability.
Solution Approach 2:
The patent introduces a guide element as an intermediary component in the housing to route and secure the winding wire. This guide element provides a mechanical anchoring point and routing path for the winding wire, enabling reliable electrical connections without requiring traditional contacting devices on the insulating end disc. The guide element mediates between the winding wire and the housing structure.
2Volume of moving object
If the stator size is reduced for compact motor design, then the installation space on the insulating end disc decreases, but this limits the size and mechanical strength of terminating domes and contacting devices
Solution Approach 1:
The patent extracts the electrical connection function from the insulating end disc area and relocates it to the housing structure. By routing the winding wire through a guide element in the housing and connecting to motor electronics externally, the design eliminates the need for installation space on the insulating end disc for terminating domes and contacting devices, enabling compact stator design without compromising connection capability.
Solution Approach 2:
The patent moves the connection interface from the two-dimensional insulating end disc surface to the three-dimensional housing structure. The winding wire is routed through space along the housing and connected externally, utilizing spatial routing in multiple dimensions rather than being constrained to the limited surface area of the insulating end disc. This enables compact stator design while maintaining adequate connection capabilities.
3Reliability
If additional attachment elements are added to secure the winding wire, then connection reliability improves, but the device complexity increases
Solution Approach 1:
The patent merges the winding wire routing function and the mechanical anchoring function into a single integrated guide element in the housing. This guide element simultaneously provides structural support, wire routing guidance, and mechanical retention, eliminating the need for separate attachment elements like clips, screws, or adhesives. The merging of functions reduces component count while maintaining connection reliability.
Solution Approach 2:
The guide element in the housing is designed to automatically secure the winding wire through its geometric structure, such as a recess or channel that mechanically retains the wire without requiring additional fastening elements. The structure itself provides the securing function, making the system self-sufficient and eliminating the need for extra attachment components.
Data Source
AI summary
A stator winding of a sheet-metal stator for an electric motor. A stator lamination stack of the stator is equipped with an insulating end plate. Stator teeth protruding in the radial direction are wound with a winding wire. After a specified number of stator teeth, the winding wire is guided away from the stator lamination stack and then back to the stator lamination stack, thereby forming an at least U-shaped loop. The loop is then used to contact a motor electronics unit of the electric motor.