Winding Support Assembly with Integrated Infrared Sensor
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Solution Overview
Problem
Existing electric machines face issues with unreliable routing and connection of lead-out wires, and temperature sensors are not effectively integrated to monitor critical parameters like winding temperature, leading to potential motor failure due to thermal coupling and undefined air gaps.
Innovation Solution
An electric machine with a stator featuring grooves for end turns and a winding support assembly that includes a built-in measuring system, such as temperature sensors, vibration sensors, and an evaluation unit, which can be contactless and securely embedded within the motor structure to monitor parameters like temperature, vibrations, and noise, ensuring reliable operation even under shock and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are mechanically attached to the winding using cable ties and resin, then the sensors can be mounted on the winding, but an undefined air gap is created that changes the time constant of protective circuits and makes motor protection unreliable
Solution Approach 1:
The patent combines the temperature sensor mounting function with the winding support assembly structure. The sensor is integrated into the winding support assembly, which is then positioned against the stator end face, eliminating the need for separate cable tie and resin mounting methods. This merging ensures a defined air gap while maintaining reliable sensor attachment.
Solution Approach 2:
The patent replaces the mechanical attachment system (cable ties and resin) with a structural integration system where the sensor is built into the winding support assembly. This substitution eliminates the undefined air gap problem by providing a precise, reproducible mounting geometry through the assembly's designed contact surface against the stator.
2Reliability
If sensors are integrated in the winding support assembly, then the sensors are securely attached and protected during vibration and shock, but the device complexity increases
Solution Approach 1:
The winding support assembly is designed to perform multiple functions: it provides mechanical support for the winding, guides lead-out wires through its structure, and serves as the mounting platform for temperature sensors. This multi-functionality reduces overall device complexity by consolidating multiple components into one integrated assembly.
Solution Approach 2:
The temperature sensor is nested within the winding support assembly structure. The sensor is positioned in a recess or mounting feature of the assembly, which is then positioned against the stator end face. This nesting arrangement protects the sensor while maintaining a compact overall structure.
3Ease of manufacture
If lead-out wires are connected by manual welding or soldering with insulating tubing and cable ties, then the connections can be made, but the routing and connection reliability is poor
Solution Approach 1:
The winding support assembly is pre-formed with integrated wire guiding features and mounting structures. Lead-out wires are routed through predefined channels and paths in the assembly during manufacturing, ensuring proper routing before final assembly. This preliminary structuring of wire paths improves connection reliability while maintaining ease of manufacture.
Solution Approach 2:
The winding support assembly provides self-guiding features for lead-out wires, such as integrated channels, grooves, or routing paths built into the structure. These features automatically guide wires through the correct route without requiring complex external fixtures or manual positioning, improving both reliability and manufacturability.
Data Source
AI summary
An electric machine, in particular a motor, includes a winding support assembly and a measuring system, preferably an infrared measuring system, The measuring system has at least one sensor and an evaluation unit, whereby the measuring system is integrated in the winding support assembly. The infrared sensor, which operates without making contact with the winding support assembly, provides almost instantaneously a measurement value that is proportional to the actual temperature of the winding system, thereby significantly improving motor protection. The sensor can be embedded and sealed in the winding support assembly.