Stator Wiring Unit Layout for Compact Coil Connection
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Solution Overview
Problem
Existing electric motor manufacturing processes are inefficient, costly, and lack a stable, compact design for connecting stator coils, particularly in synchronous motors with individual stator tooth segments.
Innovation Solution
A method involving a connection unit with interconnection elements, a support part made of insulating material, and laser welding to connect coil terminals in a star configuration, using prefabricated insulating parts and rivet pins for secure, compact, and cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional wiring methods (busbars, connecting rings, conductor tracks) are used to connect stator coils, then electrical connections can be established, but the manufacturing process becomes complex, costly, and time-consuming
Solution Approach 1:
The patent combines multiple functions into a single integrated connection element. The connection element integrates electrical conduction (through conductive material), mechanical support (through the body structure), and insulation (through insulating material) into one component, eliminating the need for separate busbars, connecting rings, and insulating structures, thereby simplifying the wiring system and reducing manufacturing complexity
Solution Approach 2:
The connection element is designed as a multi-functional component that simultaneously performs electrical connection, mechanical support, and insulation functions. This universal design allows a single component to replace multiple traditional wiring elements, streamlining the manufacturing process and reducing the number of assembly steps required
2Reliability
If multiple separate wiring components are used to connect coils, then reliable electrical connections can be achieved, but the stator assembly occupies more space and has a larger footprint
Solution Approach 1:
By merging conduction, support, and insulation functions into a single integrated connection element, the patent reduces the total volume occupied by wiring components. The consolidated design eliminates gaps and overlapping structures between separate components, resulting in a more compact stator assembly while maintaining connection reliability through the integrated multi-functional design
3Ease of manufacture
If conventional assembly methods are used for connecting stator coils, then connections can be established, but production time increases and manufacturing costs rise
Solution Approach 1:
The connection element is designed as a pre-fabricated integrated component with all necessary functions (conduction, support, insulation) built-in before assembly. This preliminary preparation allows for rapid installation into the stator without requiring complex on-site assembly steps, thereby increasing production speed while maintaining ease of manufacture
Solution Approach 2:
The integration of multiple functions into a single connection element reduces the number of assembly operations required. Instead of installing separate busbars, connecting rings, and insulating components, the multi-functional connection element can be installed as one unit, significantly reducing assembly time and improving productivity
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 easier, more stable, and cost-effective manufacturing of electric motors with reduced production costs and a compact design by ensuring secure electrical connections and efficient use of space.
Implementation Method 1
laser welding to connect coil terminals
Data Source
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AI summary
The invention relates to an electric motor comprising a rotor arranged such that it can rotate about an axis of rotation and comprising a stator, wherein the stator has multiple coils, wherein each coil has two coil connections, wherein the coils are wired together by means of a wiring unit, wherein the wiring unit comprises a carrier part for receiving multiple spaced-apart wiring elements, wherein first wiring elements are provided, wherein each of the first wiring elements has two respective spaced-apart contacting regions and a connection region connected to the contacting regions, wherein the contacting regions of each first wiring element are each connected to one of the coil connections at a respective connection point, wherein the region covered by the connection region of one of the first connectionwiring elements in the circumferential and radial direction overlaps with a respective region covered by the connection region of another of the first wiring elements in the circumferential and radial direction, wherein the first wiring elements are designed to be structurally identical.