Bus-bar Assembly for 3-Phase Brushless DC Motor
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Solution Overview
Problem
Existing bus-bar structures for 3-phase brushless DC motors complicate assembly, reducing workability and productivity due to the need for individual coil connections to bus-bars, leading to cumbersome and inefficient electrical connections.
Innovation Solution
A new bus-bar assembly design featuring a bus-bar with connecting terminals on a circular bus, a housing, and a PCB housing with power connecting portions, where the bus-bar housing is coupled to a stator assembly, facilitating easier assembly and electrical connections through a shaft and bearing system, and secure coil connections via fusing welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional bus-bar structures are used with individual coil connections, then electrical connection reliability is maintained, but assembly complexity increases and workability deteriorates
Solution Approach 1:
The patent merges multiple individual bus-bar connections into a single integrated bus-bar assembly. The bus-bar is configured as one unified component with multiple connection points, allowing all coil connections to be made through a single assembly operation rather than multiple separate connections, thereby simplifying the assembly process and improving workability
Solution Approach 2:
The bus-bar assembly serves multiple functions simultaneously: it provides electrical connections for all coils, acts as a structural support element, and facilitates simplified assembly through its integrated design. The universal design allows the same component to handle multiple connection tasks, reducing the number of separate parts needed
2Productivity
If individual coil ends are connected to bus-bar terminals, then electrical connection is achieved, but productivity decreases due to time-consuming assembly
Solution Approach 1:
The bus-bar is pre-configured with all necessary connection points and routing paths before assembly. The connection terminals are pre-positioned and the bus-bar geometry is pre-determined to optimize connection efficiency, allowing workers to simply connect coils without complex positioning or alignment steps, thereby reducing assembly time and improving productivity
3Ease of manufacture
If complex power connector structures are used, then connection reliability is improved, but device complexity increases and workability is reduced
Solution Approach 1:
The patent extracts the essential connection function from the complex power connector structure, retaining only the necessary elements for electrical connection. The design removes unnecessary components and simplifies the connector to its core functional elements, achieving reliable electrical connection without the complexity of the original power connector design
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 new bus-bar assembly improves workability and productivity by simplifying the assembly process, reducing the size of the bus-bar, and ensuring reliable electrical connections, thus enhancing the motor's overall efficiency and ease of manufacturing.
Implementation Method 1
the contact portion and the coil may be further secured to each other by fusing welding
Data Source
AI summary
Disclose herein is a motor. The motor includes a stator assembly that has a stator core, an upper insulator covering and insulating an upper portion of the stator core, and a lower insulator covering and insulating a lower portion of the stator core, and a bus-bar assembly that has a bus-bar having a plurality of connecting terminals formed on a circular bus and a contact portion electrically connected to a coil, and a bus-bar housing accommodating the bus-bar therein. The contact portion has a bent portion formed by bending distal ends of the connecting terminals upward, a contact piece located to face the bent portion, and a connection piece which connects the bent portion with the contact piece, and the bus-bar housing is coupled to a bus-bar seat defined in a central portion of the upper insulator.