Switching Unit Mounting for Electric Motor Winding Wire Ends
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Solution Overview
Problem
Conventional methods for connecting winding wire ends to connecting conductors in electric motors are sensitive to positional tolerances, making reliable electrical connections challenging, especially when using welding techniques like laser welding.
Innovation Solution
A method and assembly that utilize a positioning element to bring winding wire ends into abutment with connecting conductors, compensating for positional tolerances, and then connect them using laser welding, ensuring a simple and reliable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding method (laser welding) is used to connect winding wire ends to connecting conductors, then connection reliability is improved, but sensitivity to positional tolerances increases
Solution Approach 1:
A positioning element is introduced as an intermediary component between the winding wire ends and the connecting conductors. This positioning element compensates for positional tolerances by providing a mechanical interface that ensures proper alignment during the welding process, thereby enabling reliable laser welding connections without requiring extremely tight manufacturing tolerances on the individual components
Solution Approach 2:
The positioning element is used to pre-align and secure the winding wire ends to the connecting conductors before the welding process begins. This preliminary positioning action ensures that the components are correctly aligned and held in place during welding, preventing misalignment issues that would compromise connection reliability
2Manufacturing precision
If brazing is used to connect winding wire ends to connecting conductors, then insensitivity to positional tolerances is achieved, but connection reliability for welding applications is reduced
Solution Approach 1:
The positioning element serves as a mediator that enables the transition from brazing to welding by providing the precise alignment necessary for welding while maintaining the benefit of tolerance compensation. This allows the system to achieve both positioning insensitivity and welding connection reliability simultaneously
3Ease of manufacture
If a positioning element is used to bring winding wire ends into abutment with connecting conductors, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The positioning element is designed to perform multiple functions: it positions the winding wire ends, compensates for tolerances, and facilitates the welding process. By consolidating these functions into a single component, the overall device complexity is minimized while maintaining ease of manufacture
Solution Approach 2:
The positioning element is designed to self-align and self-position the winding wire ends relative to the connecting conductors without requiring additional complex positioning mechanisms or manual adjustment, thereby simplifying the manufacturing process
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 method provides a reliable and easy-to-produce electrical connection between winding wire ends and connecting conductors, overcoming the sensitivity to positional tolerances and ensuring consistent performance in electric motor assembly.
Implementation Method 1
The positioning element may be operatively connected to the winding wire ends and deflects the winding wire ends by moving in the plane of movement so that the winding wire ends get into a contacting abutment with the connecting conductors
Implementation Method 2
the winding wire ends can be connected to the connecting conductors by welding, in particular by laser welding, so that a reliable electrical connection easy to produce may be created
Data Source
AI summary
A method for mounting a switching unit on a component of an electric motor, including a component of an electric motor. The component may include a plurality of teeth and coil windings, arranged on the teeth and are formed by winding wire portions, the winding wire portions protruding from the coil windings by means of winding wire ends. A switching unit, which has an arrangement of connecting conductors, is arranged on the component of the electric motor. At least some of the winding wire ends are connected to the connecting conductors of the switching unit. In order to connect the winding wire ends to the connecting conductors of the switching unit, a positioning element, operatively connected to the winding wire ends, and the switching unit are moved relative to each other along a movement plane and the winding wire ends are thereby brought into contact with the connecting conductors.