Stator Winding to Inverter PCB Direct Weld Connection
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Solution Overview
Problem
The existing connection between the stator winding and the power output stage of an inverter in electric machines is complex, costly, and prone to thermal measurement inaccuracies due to the use of expensive busbars and external temperature sensors.
Innovation Solution
A direct, form-fitting connection between the coil end piece of the stator winding and the circuit board of the inverter, with an elastic connecting section and integrated current and temperature sensors, such as copper strips or NTC temperature sensors, eliminates the need for busbars and external sensors, reducing production costs and improving thermal measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars with plastic holders are used to connect the stator winding to the power output stage, then the connection is established, but the device complexity and production costs increase
Solution Approach 1:
The patent extracts and eliminates the intermediate busbar and plastic holder components from the connection path. Instead of using traditional busbars with plastic holders, the coil end piece is directly welded to the circuit board, removing unnecessary intermediate elements and simplifying the overall connection structure.
Solution Approach 2:
The patent merges the connection function directly into the circuit board by welding the coil end piece directly to the power output stage contacts on the circuit board. This combines multiple functions (electrical connection, mechanical support, thermal management) into a single integrated solution, reducing device complexity.
2Reliability
If bent and soldered busbars are used for connection, then the electrical connection is achieved, but the material costs and production costs increase
Solution Approach 1:
The patent removes the expensive busbar material and the complex bending and soldering processes from the manufacturing workflow. By directly welding the coil end piece to the circuit board, it eliminates the need for separate busbar fabrication, bending, and soldering operations, significantly reducing production costs.
Solution Approach 2:
The patent uses a simpler, more cost-effective connection method that replaces expensive, labor-intensive busbar fabrication with a more economical direct welding process. This approach uses readily available materials and simpler manufacturing techniques, reducing both material and production costs.
3Measurement precision
If external temperature sensors with plugs are used, then the temperature measurement is implemented, but the cost increases and measurement accuracy decreases due to thermal interference
Solution Approach 1:
The patent integrates the temperature sensor directly into the connection structure between the coil end piece and the circuit board. This merging of the sensor into the existing connection path eliminates the need for separate external sensors and plugs, reducing device complexity while improving measurement accuracy by minimizing thermal interference paths.
Solution Approach 2:
The patent uses the connection structure itself as an intermediary to transmit temperature information directly to the control unit. By making the connection structure temperature-sensing capable, it eliminates the need for separate sensing elements and reduces thermal interference that would occur with external sensors and their connecting cables.
4Reliability
If complex busbar geometries with multiple bearing arrangements are used, then the connection is established, but thermal measurement becomes difficult and heat transfer interference increases
Solution Approach 1:
The patent removes the complex multi-bearing busbar geometry and replaces it with a simple direct weld connection. This extraction of unnecessary geometric complexity eliminates the multiple heat transfer paths and bearing arrangements that interfere with temperature measurement, making thermal detection straightforward while maintaining connection stability.
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 simplifies the production process, reduces material costs, minimizes faults and line resistances, and provides accurate thermal and current measurements by integrating sensors directly onto the circuit board, enhancing the mechanical stability and measurement precision of the connection.
Implementation Method 1
a coil end piece (7) of the stator winding (6), which coil end piece extends in the z direction (z), is welded or connected in a form-fitting manner directly to the circuit board (8)
Implementation Method 2
the circuit board (8) forms a connecting section (11), which is elastic in the z direction (z)
Implementation Method 3
a sensor (12) for measuring current is soldered onto the connecting section (11)
Implementation Method 4
the further sensor (13) for measuring temperature is soldered onto the connecting section (11)... the further sensor (13) comprises an NTC temperature sensor
Implementation Method 5
the sensor (12) comprises a copper strip or a shunt
Implementation Method 6
a sensor (12) for measuring current is soldered onto the connecting section (11)
Data Source
AI summary
Various embodiments may include a connection between a winding for an electric machine and a circuit board for an inverter including a connection between the winding and a circuit board for an inverter. A coil end piece of the stator winding extends in a first direction and is welded or connected in a form-fitting manner directly to the circuit board on which a power output stage of the inverter is located.