Stator Winding Connection Assembly for Automated Welding Alignment
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Solution Overview
Problem
Existing connection devices for stator windings in electrical machines face challenges in automated production due to the need for precise positioning and sufficient contact surface during connection to a voltage source, particularly in welding processes.
Innovation Solution
A connection device featuring an electrically insulating body with a plate-shaped base section and positioning sections, along with electrically conductive connection elements with leg sections and projections, allows for precise alignment and mechanical connection to an electrical conductor, facilitating automated production by ensuring accurate positioning and robust attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection elements are used to connect stator winding to voltage source, then electrical connection and insulation are provided, but precise positioning and sufficient contact surface are required which complicates automated manufacturing
Solution Approach 1:
The insulating body is pre-formed with integrated positioning sections (protrusions) that guide the connection elements into correct positions before the welding process. This preliminary positioning action eliminates the need for complex positioning fixtures during automated manufacturing, while ensuring reliable electrical connection through proper alignment and contact surface engagement.
2Extent of automation
If precise positioning of connection element on insulating body is achieved, then automated manufacturing is facilitated, but device complexity increases
Solution Approach 1:
The positioning sections are merged directly into the insulating body structure as integral protrusions rather than separate components. This integration provides precise positioning guidance for automated manufacturing while avoiding the complexity of additional separate positioning devices or fixtures, thus facilitating automation without proportionally increasing device complexity.
3Strength
If connection element has sufficient contact surface for welding, then reliable electrical connection is achieved, but positioning precision requirements increase
Solution Approach 1:
The positioning sections on the insulating body perform the preliminary action of aligning the connection element with the stator winding connection sections. This pre-alignment ensures that when the connection element is placed, its contact surface is automatically positioned correctly for welding, thereby reducing the precision requirements during the actual welding operation while still achieving reliable electrical connection.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Connection device (2) for a stator (3) of an electrical machine (203), comprising - an electrically insulating insulating body (13) comprising a plate-shaped base section (15) with a first side (16), with a second side (17) opposite the first side (16), and with a recess (18a-c) and a positioning section (20a-c) arranged on the first side;and - an electrically conductive connecting element (14a-c) comprising (i) two leg sections (21a, 21b) extending away from the first side (16) of the base section (15) and each having a projection (23) pointing towards the recess (18a-c), (ii) a connecting section (22) connecting the leg sections (21a, 21b) at their end facing away from the first side (16) of the base section (15), (iii) and a fastening means (24) for electrically and mechanically connecting the connecting section (22) to an electrical conductor (205) and arranged on the insulating body by the positioning section (20a-c);wherein in the recess (18a-c) two connection sections (10a-c, 11a-c) of a stator winding (5) of the stator (3) can be arranged for electrically conductive and mechanical connection with the projection (23) of the leg sections (21a, 21b) in order to form an electrically conductive connection of the connection sections (10a-c, 11a-c) via the connection element (14a-c) with the electrical conductor (205).