Electric Machine Terminal Assembly Compression Fastening

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Solution Overview

Problem

Complex geometries of electric machine components lead to burdensome assembly processes, particularly with stator terminal assemblies that require precise connection of electrical windings, often resulting in increased manufacturing complexity.

Innovation Solution

The electric machine assembly incorporates a terminal assembly with three pairs of terminal leads and lugs, where each lug is compressed to secure the leads, and bridges are used to connect the leads to end windings, simplifying the assembly process and reducing the need for extensive fixturing and weld operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If magnet wire is used for both electrical winding and terminal leads, then design simplicity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedesign simplicityVSAvoidmanufacturing complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The terminal lead assembly is segmented into distinct components: terminal leads, terminal lugs, and bridges. This segmentation allows each component to be manufactured separately with optimized processes, avoiding the manufacturing complexity that would arise from using the same material for both winding and terminal leads while maintaining design simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal lug combines multiple functions into a single component: it provides mechanical support, electrical connection, and structural attachment points. By merging these functions, the design remains simple while manufacturing becomes easier through standardized production of integrated components.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If complex geometries are used in electric machine components, then functional performance is improved, but assembly process becomes burdensome

Engineering Contradiction:

Improvefunctional performanceVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Terminal leads are pre-formed with bends and shapes required for final assembly. Bridges are pre-assembled with terminal leads before installation to the stator. This preliminary preparation of components with their final geometries eliminates the need for complex in-assembly operations, reducing assembly burden while maintaining functional performance.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Bridges serve as intermediary components that simplify assembly by providing pre-configured connection paths between terminal leads and end windings. These intermediaries handle the complex geometries and connections, making the overall assembly process more straightforward while achieving the required functional performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If extensive fixturing and weld operations are used, then connection precision is improved, but assembly time increases

Engineering Contradiction:

Improveconnection precisionVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Traditional weld operations are replaced with mechanical compression and deformation methods. Terminal lugs are compressed to deform and secure terminal leads through cold forming rather than welding. This substitution eliminates time-consuming weld operations while maintaining connection precision through controlled mechanical deformation and secure mechanical interlocking.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connection process changes from thermal welding to mechanical compression with controlled deformation parameters. By changing the fundamental parameter from temperature-based joining to force-based deformation, assembly time is reduced while connection precision is maintained through controlled compression forces and deformation geometry.

Inventive Principle:

Principle #35Parameter changes

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 minimizes assembly complexity, reduces the number of required weld operations, and streamlines the connection process, enhancing efficiency and reducing cycle time by focusing on aligning and securing three wire pairs rather than multiple individual wires.

Implementation Method 1

Each terminal lug is compressed at one of the sides to deform a respective terminal lug and secure each of the pair of terminal leads within one of the pair of terminal lead through-holes

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS11411460B2Electric machine assembly and method to assemble

Publication Date: 2022.08.09 FORD GLOBAL TECH LLC

AI summary

An electric machine assembly including a terminal assembly and three terminal lugs is provided. The terminal assembly may include three pairs of terminal leads. Each of the three terminal luges may define a pair of terminal lead through-holes and a pair of opposing radial sides. Each terminal lug may be compressed at one of the sides to deform a respective terminal lug and secure each of the pair of terminal leads within one of the pair of terminal lead through-holes. The assembly may further include a stator disposed within a housing and include end windings. Each of the terminal leads may include a base terminal portion. The terminal assembly and the stator may be arranged with one another such that each base terminal portion is aligned with one of the end windings for securing thereto. The assembly may further include three bridges.