Stator Wiring Unit Layout for Simpler Multiphase Motor Assembly
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Solution Overview
Problem
Conventional electric motor manufacturing processes are complex and costly, particularly in connecting stator coils, which hinders efficient production and stability of multiphase windings.
Innovation Solution
A wiring unit with a carrier part made from insulating material, featuring multiple wiring elements connected via laser welding or alternative methods, ensures secure and compact electrical connections between stator coils, facilitating a star or delta connection configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wiring methods are used to connect stator coils, then the coils can be connected to form multiphase windings, but the production process becomes complex and costly
Solution Approach 1:
The patent combines multiple wiring elements into a single integrated wiring unit that simultaneously connects multiple coil connections. The wiring unit includes a carrier component with multiple wiring elements arranged in a specific pattern, allowing simultaneous connection of multiple coils in a single assembly operation, thereby simplifying the manufacturing process while maintaining connection reliability
Solution Approach 2:
The wiring unit is segmented into a carrier component and multiple wiring elements, where each wiring element can be independently positioned and connected to specific coil connections. This segmentation allows for standardized modular assembly, reducing production complexity while enabling flexible configuration for different motor designs
2Productivity
If multiple individual wiring operations are performed to connect coil connections, then reliable electrical connections are achieved, but production time and cost increase
Solution Approach 1:
The wiring elements are pre-positioned and pre-configured on the carrier component before assembly with the stator. This preliminary arrangement of wiring elements in the correct spatial configuration allows for rapid assembly with the coils, eliminating time-consuming on-site wiring operations and significantly improving production efficiency
Solution Approach 2:
Multiple wiring operations are merged into a single assembly operation where the entire wiring unit is installed simultaneously with all wiring elements making contact with their respective coil connections in one step, thereby reducing total production time while maintaining connection 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
This approach simplifies and cost-reduces the production of electric motors by enabling stable, compact, and efficient electrical connections between stator coils, enhancing the motor's reliability and manufacturing efficiency.
Implementation Method 1
the contacting regions, in particular all contacting regions, of each first wiring element being connected to one of the coil connections at a connection point in each case, in particular electrically connected, in particular integrally connected with the aid of laser welding
Data Source
AI summary
An electric motor includes a rotor and a stator, the stator having multiple coils, each coil having two coil connections, the stator in particular having multiple stator segments, and each stator segment having precisely one coil, the coils being connected to one another with the aid of a wiring unit, the wiring unit having a carrier part for accommodating multiple wiring elements set apart from one another.