Stator Wiring Support Structure for Vibration-Resistant Coil Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stators in electrical machines face challenges in providing adequate radial support for connection devices, leading to operational vibrations and increased risk of wire breakage due to relative movements between the stator and interconnection device.
Innovation Solution
A stator design with a connection device that incorporates axial connecting means for secure axial positioning and independent radial support means to mitigate vibrations, featuring a decoupled radial gap in the axial connections to reduce mechanical stress on the coil ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connection elements are used for each wire end in a wire bundle, then reliable electrical connection is achieved, but the number of components and assembly complexity increases significantly
Solution Approach 1:
Multiple separate connection elements are merged into a single common connection element that can electrically connect all wire ends in the bundle simultaneously. This reduces the number of components from multiple individual connectors to one shared connector, simplifying the overall connection structure while maintaining reliable electrical connections across all wires.
Solution Approach 2:
The common connection element is designed to serve multiple functions: it provides electrical connection for all wire ends in the bundle, structural support for the wire bundle, and positioning functionality. This multi-functional design eliminates the need for separate components for each function, reducing complexity while ensuring reliable connections.
2Ease of operation
If wire bundles with loose wire ends are used, then ease of connection is achieved, but precise positioning and stable electrical connection become difficult
Solution Approach 1:
The wire bundle is pre-structured with positioning elements and guiding features before the actual electrical connection is made. This preliminary structuring ensures that wire ends are automatically positioned correctly when inserted into the common connection element, eliminating the need for precise manual positioning during assembly while maintaining manufacturing precision.
Solution Approach 2:
Positioning elements and guiding structures act as intermediaries between the loose wire ends and the common connection element. These intermediaries facilitate easy insertion of wire ends while ensuring they reach the correct positioned contact points, bridging the gap between ease of operation and positioning precision.
3Reliability
If complex connection structures are used to secure wire bundles, then stable electrical connection is achieved, but assembly time and manufacturing cost increase
Solution Approach 1:
The connection structure is segmented into modular components: the common connection element, positioning elements, and wire bundle structure are designed as separate but complementary modules. This segmentation allows for simple, rapid assembly of each module independently, then quick integration, improving assembly speed while maintaining stable electrical connections through the coordinated function of each segment.
Solution Approach 2:
The wire bundle structure and common connection element are designed to self-align and self-secure during assembly. Positioning elements automatically guide wire ends into correct positions, and the structure provides inherent retention forces that secure connections without requiring additional fastening operations, thereby increasing assembly speed while ensuring stable electrical connections.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a stator (10) in an electric machine (1) with a laminated core (11) formed in an annular fashion about a central axis (A), on which core stator coils (16) with coil ends (16a, b) are arranged by means of formers (12a, 12b). The stator (10) comprises wiring device (20), on which a plurality of mutually isolated connecting conductors (22-26) with coil connection areas (22a–26a) are present for connecting the stator coils (16). The wiring device (20) is joined on the stator in an axial joining direction to the stator coils (16) and is secured by axial connection means (30a, b) to the formers (12a), thus forming a plurality of axial connections (32a, b). According to the invention, to increase the stiffness of the stator (10), radial supporting means (40, 41) are additionally formed on the wiring device (20) to interact with the formers (12a), said means being designed to be functionally independent of the axial connection means (30a, b).