Brushless Fan Motor Wiring Without Busbars to Cut Welds
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Solution Overview
Problem
The use of busbars in brushless electric motors for vehicle heat treatment modules increases material and welding costs due to the need for multiple welds, which can reduce reliability.
Innovation Solution
A brushless electric motor design that eliminates busbars by directly welding the power circuit to the electrical conduction device and the stator, using a molded support made of dielectric material to prevent short circuits and reduce the number of welds, thereby lowering material costs and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are used for wiring between the electrical power supply and the electronic circuits or between the electronic circuits and the stator, then the electrical connection reliability is improved, but the material costs and welding costs increase significantly
Solution Approach 1:
The patent extracts and eliminates the busbar component from the system by establishing direct welding connections between the electronic circuits and the stator, and between the electrical conduction device and the power circuit. This removal of the intermediate busbar component reduces material costs while maintaining connection reliability through direct welding joints.
Solution Approach 2:
The patent merges previously separate components by directly welding the electronic circuits to the stator and the electrical conduction device to the power circuit. This consolidation eliminates the need for separate busbars and reduces the total number of welding operations, thereby reducing both material and labor costs while maintaining electrical connection reliability.
2Reliability
If busbars are used for electrical connections, then the electrical connection reliability is improved, but the number of welding points increases which reduces reliability
Solution Approach 1:
The patent removes the busbar component that necessitated multiple welding points. By directly welding the electronic circuits to the stator and the electrical conduction device to the power circuit, the system eliminates intermediate connection points, thereby reducing the total number of welds while maintaining or improving reliability through fewer potential failure points.
Solution Approach 2:
The patent combines previously separate electrical connection paths into direct welds. Instead of welding busbars to multiple components, the electronic circuits are directly welded to the stator and the electrical conduction device is directly welded to the power circuit, reducing the number of welding operations and potential failure points.
3Reliability
If busbars are used to connect the electrical power supply to the electronic circuits and the stator, then the electrical conductivity is improved, but the assembly complexity and manufacturing time increase
Solution Approach 1:
The patent eliminates the busbar component from the assembly process. By directly welding the electronic circuits to the stator and the electrical conduction device to the power circuit, the assembly process is simplified, reducing the number of parts to be handled and installed, thereby increasing assembly speed and productivity while maintaining electrical conductivity.
Solution Approach 2:
The patent merges the electrical connection functions into direct welds between components. This consolidation reduces the number of assembly steps and parts handling, streamlining the manufacturing process and increasing productivity while ensuring proper electrical conductivity through direct metal-to-metal connections.
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 design reduces material costs and enhances the reliability of electrical connections by minimizing the number of welds and using a dielectric support to prevent short circuits, improving the overall efficiency and durability of the motor-fan unit.
Implementation Method 1
the support comprises a dielectric material. This makes it possible to prevent short circuits.
Implementation Method 2
one end is welded directly to an electrical conduction device
Data Source
AI summary
The present invention relates to a brushless electric motor for rotating a fan of a motor-driven ventilation unit of a vehicle, the motor comprising a rotor, a stator equipped with at least two coils, a casing housing a power circuit (15) and a servo circuit (13) for controlling the power circuit.