Stator Wiring Connection Device with Automatic Conductor Positioning
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Solution Overview
Problem
The connection of stator wiring in electrical machines is complex and error-prone, especially for wave windings, and existing solutions do not ensure reliable and simple interconnection, nor do they provide adequate sealing against oils or liquids.
Innovation Solution
A device with a base body featuring positioning means that automatically align and connect electrical conductors using guide and interconnection sections, allowing for various welding methods and ensuring effective sealing, comprising a base body with insertion openings, guide sections, and interconnection sections that form a sleeve system for easy and reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring connection methods are used in the smallest spaces, then the wiring can be connected, but the connection process becomes complex and error-prone requiring further work steps
Solution Approach 1:
The connection device is divided into multiple positioning means, each with guide sections and interconnection sections. This segmentation allows individual conductors to be positioned and connected independently, simplifying the overall complex connection process while maintaining high reliability through systematic organization of connection elements
Solution Approach 2:
The positioning means with guide sections and interconnection sections act as intermediary elements between the conductors and the final connection point. These intermediaries automatically guide and position conductors, eliminating the need for complex manual positioning steps and reducing errors in the connection process
2Manufacturing precision
If manual positioning of electrical conductors is performed, then connections can be established, but further error-prone work steps are required
Solution Approach 1:
The positioning means are designed to automatically guide and position conductors through their guide sections and interconnection sections without requiring manual intervention. The conductors self-align and self-position within the positioning means, eliminating time-consuming manual positioning steps while ensuring precise alignment for reliable connections
Solution Approach 2:
The positioning means are pre-configured with guide sections and interconnection sections that automatically perform the positioning function before the actual connection takes place. This preliminary automatic positioning action ensures precise conductor alignment is achieved before welding or other connection methods are applied, eliminating the need for subsequent error-prone adjustment steps
3Object-affected harmful factors
If conventional connection devices are used, then wiring can be interconnected, but sealing against oil or liquids is not sufficiently guaranteed
Solution Approach 1:
The positioning means with interconnection sections are nested within the connection device housing, creating a hierarchical protective structure. The interconnection sections are positioned within the housing in such a way that they are automatically sealed when the housing is closed, providing protection against oil and liquids without requiring complex additional sealing components
Solution Approach 2:
The housing of the connection device acts as a flexible shell that provides sealing protection for the internal positioning means and interconnection sections. The housing design allows for effective sealing against oil and liquids while maintaining manufacturing simplicity through conventional housing fabrication methods
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
In order to provide a device (100) for connecting the wiring of a stator (10) of an electric machine, by means of which automatic positioning of electrical conductors (17) in the wiring is achieved, the invention proposes a device (100) for connecting the wiring of a stator (10) of an electric machine, comprising a base (11) having an underside (12), wherein the base (11) can be placed onto a stator (10) via its underside (12); the base (11) comprises at least one positioning means (14) for positioning at least one electrical conductor (17) in a wiring of the stator (10); the positioning means (14) comprises an insertion opening (26); the insertion opening (26) is arranged on the underside (12) of the base (11) such that, when the device (100) is placed onto the stator (10), the at least one electrical conductor (17) can be inserted into the positioning means (14) through the insertion opening (26); the positioning means (14) comprises a guide section (27) and a connection section (16); and the positioning means (14) is configured in such a way that, when the base (11) is placed onto the stator (10), the at least one electrical conductor (17) is guided into the connection section (16) by the guide section (27).