Motor Stator Wire Terminal Joint Sealing Design
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Solution Overview
Problem
The existing wire terminal joints of motor stator windings experience poor sealing due to heat-shrinkable tubes shrinking, leading to gaps and a shorter service life.
Innovation Solution
A wire terminal joint design featuring an external power wire with a core interwound and electrically connected to exposed aluminum-enameled wires, using a first sleeve with a larger diameter than a second sleeve, where the first sleeve is thermally-bonded or riveted to the second sleeve, creating a compact structure for improved sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat-shrinkable tube is used to seal and protect the wire terminal, then the wire terminal is protected, but the tube shrinks upon thermal treatment producing large gaps and poor sealing
Solution Approach 1:
The sealing structure is divided into multiple segments: an inner sleeve that fits tightly around the wire terminal and an outer sleeve that provides additional protection. This segmentation allows each sleeve to perform its specific function without the deformation problems of a single heat-shrinkable tube, maintaining consistent sealing contact throughout thermal treatment.
Solution Approach 2:
The inner sleeve is nested within the outer sleeve, creating a layered protective structure. The inner sleeve directly contacts the wire terminal while the outer sleeve provides additional sealing and mechanical protection. This nested arrangement ensures that both sleeves work together to maintain consistent sealing without the shrinkage-induced gaps that plague single-tube designs.
2Reliability
If soldering or crimping is used to connect the aluminum-enameled wire and external power wire, then electrical connection is achieved, but the connection reliability is insufficient
Solution Approach 1:
The connection structure merges the electrical connection function and mechanical securing function into a single integrated terminal block design. The aluminum-enameled wire and external power wire are both inserted into the same terminal block, where they are simultaneously electrically connected and mechanically secured, eliminating the need for separate soldering and crimping operations.
Solution Approach 2:
The invention extracts the connection process from traditional multi-step procedures (soldering then crimping) and replaces it with a single insertion operation. The terminal block is designed to automatically establish both electrical and mechanical connections upon wire insertion, removing the complexity of multiple connection steps while improving reliability.
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
The design achieves a compact structure, high reliability, and extended service life by enhancing the sealing properties of the wire terminal joint, addressing the poor sealing issues of existing technologies.
Implementation Method 1
The first sleeve is sleeved on the external surfaces of the external power wire and the second sleeve, and is thermally-bonded the second sleeve.
Data Source
AI summary
A wire terminal joint of a motor stator winding, including: an external power wire, the external power wire including a core extending from one end thereof; a plurality of aluminum-enameled wires, each aluminum-enameled wire including an exposed aluminum wire at one end thereof; a first sleeve; and a second sleeve. The aluminum-enameled wires are disposed on the motor stator winding. The core extending from one end of the external power wire is interwound with and electrically connected to the exposed aluminum wire. The first sleeve has a larger diameter than the second sleeve. The second sleeve is sleeved on the core and the exposed aluminum wire. One end of the first sleeve is sleeved on external surfaces of the external power wire and the exposed aluminum wire, and another end of the first sleeve is sleeved on an external surface of the second sleeve.