Tubular Flat Insulation for Automated Stator and Rotor Wiring

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Solution Overview

Problem

Existing methods for wiring and insulating electrical conductors in electric machines, particularly in stators and rotors, are complex and difficult to automate, leading to inefficiencies in production and increased costs.

Innovation Solution

A wiring element with a flat insulation element that surrounds the conductor ends, fixed by bonded and form-fitting connections, allowing for automated assembly and improved insulation properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If traditional insulation methods (tube systems, insulating bandages) are used for wiring elements, then electrical insulation is provided, but the process cannot be easily automated and requires great effort for axial joining and accessibility

Engineering Contradiction:

Improveautomation of wiring and insulating processVSAvoidcomplexity of wiring and insulating process

Core Design Contradiction:

Extent of automationVSEase of manufacture

Solution Approach 1:

The insulation system is segmented into a modular insulation kit containing pre-cut flat insulation elements, adhesive strips, and surrounding insulation elements. Each component is independently prepared and can be automatically applied to wiring elements, enabling automation while simplifying the manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Flat insulation elements are pre-cut to specific dimensions and pre-equipped with adhesive strips before assembly. This preliminary preparation eliminates the need for complex on-site cutting and adhesive application operations, making the wiring process automatable and significantly reducing manufacturing effort.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If complex automation methods are implemented for axial joining of tube systems onto flexible connecting wires, then wiring can be automated, but the process becomes comparatively complex and difficult to implement

Engineering Contradiction:

Improveautomation capability of wiring processVSAvoidcomplexity of automation system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The complex automation requirements for axial joining of tube systems are extracted and replaced by applying flat insulation elements in a different manner. The insulation elements are wrapped around and bonded to the wiring elements, eliminating the need for complex axial joining mechanisms while maintaining automation capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Adhesive strips serve as an intermediary between the flat insulation elements and the wiring elements. This simple bonding mechanism replaces complex mechanical joining systems, enabling automation with minimal device complexity while achieving reliable insulation attachment.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Extent of automation

If alternative insulating bandages are used, then some automation is possible, but accessibility of the joining/insulation point remains limited

Engineering Contradiction:

Improveautomation of insulating processVSAvoidaccessibility of joining/insulation point

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

Flat insulation elements in the form of thin flexible films or sheets are used instead of rigid bandages. These thin films can be easily wrapped around wiring elements and bonded in place, providing excellent accessibility to the insulation point while enabling full automation of the insulating process.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Enables efficient, automated production of compact and flexible insulation for stators and rotors, reducing material and logistics costs while enhancing insulating properties.

Implementation Method 1

the first edge and the second edge are fixed relative to one another by means of a bonded connection and/or a form-fitting connection, in particular by means of an adhesive strip

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

the insulation is made of a flat insulation element that at least partly surrounds the wiring element

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS20250392181A1Wiring element, stator, rotor, method for producing a stator, method for producing a rotor, and kit of parts

Publication Date: 2025.12.25 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

The disclosure relates to a wiring element, in particular for electrically contacting two mutually spaced contact elements, comprising a first wire end and a second wire end. The wiring element has an insulation between the first wire end and the second wire end, wherein the insulation is made of a flat insulation element that at least partly surrounds the wiring element and has a first edge extending in the longitudinal extension of the wiring element and a second edge extending in the longitudinal extension of the wiring element. The first edge is fixed relative to the second edge of the flat insulation element by means of a bonded connection and/or a form-fitting connection such that the wiring element is surrounded by the flat insulation element in a tubular manner.