Stator Wire Guide Clamping Contact for Electric Motor Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator designs for electric motors, particularly in brushless electric motors for e-bikes, face challenges in easy assembly, high production time, and increased axial height due to complex wiring connections and the need for welding systems.
Innovation Solution
A stator design featuring stator teeth with multi-phase winding coils connected via phase-selective wire guides and insulation displacement contacts, allowing for clamping contact with printed circuit boards through a clamping slot system, reducing the need for welding and minimizing axial height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding systems are used to connect stator winding coils to printed circuit boards, then reliable electrical connection is achieved, but assembly complexity increases and production time increases
Solution Approach 1:
The patent replaces the welding system (thermal/mechanical process) with a mechanical clamping connection system. The clamping contact element with clamping arm and clamping surface provides reliable electrical connection through direct mechanical contact and clamping force, eliminating the need for welding equipment and processes while maintaining connection reliability.
Solution Approach 2:
The patent introduces a clamping contact element as an intermediary component between the stator winding coils and the printed circuit board. This intermediary element features insulation displacement contacts that mechanically strip insulation and create electrical contact, serving as a mediator that simplifies the connection process while ensuring reliable electrical connection without direct welding.
2Reliability
If traditional welding systems are used to connect stator winding coils, then reliable electrical connection is achieved, but production time increases
Solution Approach 1:
The mechanical clamping connection system replaces time-consuming welding processes with rapid mechanical assembly operations. The clamping contact element can be installed and secured through simple mechanical steps rather than requiring welding equipment setup, heating, cooling, and quality inspection, significantly reducing production time while maintaining connection reliability.
Solution Approach 2:
The clamping contact element is designed with pre-formed insulation displacement contacts and clamping surfaces that are prepared in advance during manufacturing. This preliminary preparation allows for rapid on-site assembly without requiring complex welding procedures, thereby reducing production time while ensuring reliable electrical connection.
3Reliability
If complex wiring connections are used in stator design, then reliable coil connections are achieved, but axial height increases
Solution Approach 1:
The patent merges multiple functions into the clamping contact element: it simultaneously provides mechanical support, electrical connection through insulation displacement contacts, and secure fastening through the clamping arm. This consolidation eliminates the need for separate wiring components and connection hardware, reducing axial height while maintaining connection reliability.
Solution Approach 2:
The clamping contact element utilizes the radial dimension for the clamping arm that extends toward the rotor, allowing the connection to be made in a radial direction rather than extending axially. This dimensional change enables reliable coil connections without increasing the axial height of the stator, as the clamping action occurs in the radial plane.
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 design simplifies assembly, reduces production time, and minimizes installation space by enabling a space-saving and secure connection of the stator winding coils to the printed circuit board without welding, thus lowering the axial height of the stator.
Implementation Method 1
insulation displacement contact for a wire section of coils connected to one another
Implementation Method 2
A spring leg formed onto the first contact leg is suitably connected in one piece to a plug-in leg
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a stator (1) of an electric motor, comprising a number of stator teeth (6) which support the coils (9) of a multi-phase stator winding (3), and with a number of pole shoe-sided wire guides (13) with first contact elements (11) inserted therein, with respectively at least one insulation displacement contact (21) having an insulation displacement opening (22), for a wire section (19) of coils (9) which are interconnected. The first contact element (11) comprises a clamping slot (23) with a clamping slot opening (24) via which a second contact element (12) of a contact system (10), which is in contact with a printed circuit board (4), is inserted or can be inserted into the clamping slot (23) forming a clamping-contact.