Stator Winding Connection Assembly for Tolerance-Stable Positioning
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Solution Overview
Problem
The irregular shape of the winding head due to manufacturing tolerances makes it difficult to precisely position connection devices for stator windings, hindering automated production in electric machines.
Innovation Solution
A stator device with a connection device featuring a plate-shaped insulating body and radially protruding holding elements that securely attach to the winding head, providing positional stability and resistance to manufacturing tolerances, and including elastically deformable elements for secure clamping and guide elements to inhibit movement of the star point conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a connection device is directly arranged axially on the winding head, then the structure is simple, but positioning precision deteriorates due to irregular winding head shape from manufacturing tolerances
Solution Approach 1:
The connection device transitions from axial arrangement to radial arrangement on the winding head. The holding elements extend radially inward to engage with the winding head periphery, changing the dimension of attachment from end-face axial contact to radial circumferential engagement, thereby achieving precise positioning despite manufacturing tolerances
Solution Approach 2:
The holding elements act as intermediaries between the connection device and the winding head. These elements protrude radially inward and engage with the winding head periphery, providing a stable interface that compensates for irregularities in the winding head shape caused by manufacturing tolerances
2Device complexity
If conventional connecting devices are used without holding elements, then the device complexity is low, but reliability deteriorates due to radial and axial slippage during production
Solution Approach 1:
The holding elements are designed to be elastically deformable, allowing them to adapt dynamically to the winding head's irregular shape. This elasticity enables the elements to maintain reliable engagement while accommodating manufacturing tolerances, preventing both radial and axial slippage during production
3Manufacturing precision
If holding elements are added to the insulating body, then positioning stability improves, but device complexity increases
Solution Approach 1:
The insulating body is segmented with multiple holding elements distributed around its circumference. Each holding element independently engages with the winding head periphery, providing distributed positioning support that enhances stability while maintaining a modular structure that is relatively simple to manufacture
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
Facilitates robust and precise automated production by preventing slipping and accommodating manufacturing variations, ensuring reliable electrical connections and improved assembly efficiency.
Implementation Method 1
the holding elements comprise holding elements of a first type, which are elastically deformable at least in sections such that they exert a restoring force on the winding head to hold the insulation body
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Stator device (1) for an electric machine (203), comprising: - a stator (3) having a stator core (4) with a longitudinal axis (6), a first end face (7) and a second end face (8) axially opposite the first end face (7) with respect to the longitudinal axis (6), and a stator winding (5) which forms a winding head (9) on the first end face (7) and has several connection sections (10a-c, 11a-c) extending beyond the winding head (9); and - a connection device (2) comprising an insulating body (13) having a plate-shaped base section (14) with a first side (15) facing away from the winding head (9) and a second side (16) facing the winding head (9), and configured to connect the connection sections (10a-c, 11a-c) to an electrical conductor (205);wherein the insulating body (13) has several retaining elements (18a-c, 19a-c) which project from the base section (14) on the second side (16) and are designed to hold the insulating body (13) radially on the winding head (9).