Brushless Motor Bus Bar Axial Guide Hole
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Solution Overview
Problem
The challenge in brushless motors for power-steering systems is the difficulty in connecting thick wires to terminals due to reduced space between adjacent terminals, which affects workability and reliability, especially when trying to reduce vibration and increase the number of teeth and packing factor in the stator.
Innovation Solution
A motor design featuring a stator with a circular or substantially circular core and tooth portions, insulated by U-shaped insulators, and a bus bar with a conductor plate and plate support that provides a sufficient axial height gap to prevent wire fall and facilitates easy wire connection, using a unique configuration with a conductor plate and plate support to position wires correctly and securely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of terminals on the bus bar is increased to accommodate more teeth, then the motor can support higher tooth counts and improve vibration reduction, but the space between adjacent terminals is reduced making wire connection difficult
Solution Approach 1:
The patent introduces a guide hole through the bus bar that extends in the axial direction, providing a new dimensional path for wire insertion. This allows wires to be guided from the axial direction rather than trying to access terminals from the radial direction, effectively adding a new dimension to the connection process and solving the space constraint problem between terminals.
2Reliability
If the number of teeth of the stator is increased to reduce vibration, then the motor achieves smoother operation, but the number of terminals on the bus bar must be increased which reduces terminal spacing
Solution Approach 1:
The guide hole structure adds an axial dimension to the terminal connection approach, allowing wires to be routed through the bus bar thickness rather than requiring sufficient radial or lateral space between terminals. This dimensional change enables higher tooth counts and more terminals without increasing the complexity of terminal spacing arrangements.
3Power
If thick wires are used in the motor for power steering system, then the motor can handle higher power requirements, but the space between adjacent terminals must be sufficiently wide for workability
Solution Approach 1:
The guide hole provides an axial passage through the bus bar that accommodates thick wires during the connection process. By routing wires through the axial dimension of the guide hole rather than requiring wide spacing between terminals in the radial plane, the patent enables the use of thick power-carrying wires while maintaining compact terminal spacing.
Data Source
AI summary
A motor includes a stator and a bus bar supported axially above the stator. The bus bar includes a concave portion arranged in a lower surface thereof facing toward coils of the stator. In a gap defined between the coil and the concave portion, a portion of the wire extracted from the coil and wound in the circumferential direction (i.e., a crossover wire portion) is accommodated. The bus bar includes a wire-positioning hole through which the wire is led to a terminal to be connected with the wire.