Stator Winding Temperature Sensor Mounting
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Solution Overview
Problem
Existing stator arrangements in electric motors face issues with temperature monitoring due to manufacturing tolerances leading to undefined contact or air gaps between temperature monitors and windings, resulting in inaccurate temperature measurements and potential motor failure from thermal destruction, along with complex manual wiring during assembly.
Innovation Solution
The temperature monitor is designed to be resiliently movable and seated in a receiving pocket that engages deeply within the stator slot with spring-elastic pretension, ensuring direct thermal contact and minimizing air gaps, while being connected to a carrier part for easy installation and pre-wiring, eliminating the need for manual wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature monitor is arranged to contact the end winding on the stator winding, then temperature monitoring function is provided, but manufacturing tolerances lead to undefined contact or air gap distance resulting in inaccurate temperature measurement
Solution Approach 1:
The receiving pocket acts as an intermediary structure between the temperature monitor and the stator winding. It provides a pre-positioned, precisely fitted interface that eliminates air gaps and ensures reliable thermal contact. The pocket's geometry is specifically designed to accommodate the temperature monitor while maintaining consistent contact pressure, thereby improving both measurement accuracy and contact reliability.
Solution Approach 2:
The receiving pocket is pre-formed in the switching disk with precise dimensions and geometry before assembly. This preliminary preparation ensures that when the temperature monitor is installed, it automatically achieves the correct position and contact pressure without requiring additional adjustment or compensation for manufacturing tolerances during final assembly.
2Ease of manufacture
If manual wiring of the temperature monitor is performed during motor assembly, then temperature monitoring function is achieved, but production complexity increases
Solution Approach 1:
The receiving pocket integrates multiple functions into a single structure: it provides mechanical support for the temperature monitor, ensures precise positioning, maintains contact pressure, and eliminates the need for separate wiring operations. By combining these functions into one integrated component, the invention simplifies the assembly process and reduces production complexity.
Solution Approach 2:
The receiving pocket is designed to automatically perform the functions of positioning and securing the temperature monitor without requiring external intervention or manual wiring operations. The structural design of the pocket itself provides the necessary constraints and connections, making the system self-sufficient and eliminating complex manual assembly steps.
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 ensures optimal heat transfer and reliable thermal monitoring, reducing the risk of temperature-related malfunctions and simplifying the installation process by maintaining consistent contact pressure and improving detection accuracy within the stator slot.
Implementation Method 1
the receiving pocket has such a thin wall that the temperature monitor is in thermally conductive contact with the stator winding directly via this thin wall
Implementation Method 2
the temperature monitor sits in the receiving pocket connected to the switching disk in a resiliently movable manner with spring-elastic pretension
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The present invention relates to a stator assembly (1) for an electric motor, comprising a stator core (2) with stator windings (6) extending through stator slots (4) and forming a winding head (8) on each end face of the stator core (2), and a connecting device (10) for the stator windings (6). The connecting device (10) has a switching disk (12) covering the winding head (8) on one end face of the stator, with at least one temperature sensor (14) mounted thereon for monitoring the temperature of the stator windings (6). The temperature sensor (14) is located in a receiving pocket (16) which is spring-elastically connected to the switching disk (12) such that it engages one of the stator slots (4) via the receiving pocket (16) and is thus pressed against the respective stator winding (6) with a spring-elastic preload.