Brushless Motor Bus Bar Segmentation for Power Steering
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Solution Overview
Problem
Conventional brushless motors for power-steering systems face challenges in reducing vibration and improving workability due to increased terminal density on the bus bar, making it difficult to connect thick wires, and requiring high reliability over extended periods.
Innovation Solution
The motor design includes a stator with a circular core back and radially extending tooth portions, insulated by U-shaped insulators, and a bus bar with a first conductor plate for connecting wire ends and a second conductor plate supported by the insulator, which connects to a neutral point, reducing the number of first terminals and increasing the space between them, enhancing workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of terminals on the bus bar is increased to accommodate more coils, then the motor can support more teeth and reduce vibration, but the space between adjacent terminals is reduced making it difficult to connect thick wires
Solution Approach 1:
The invention divides the bus bar into multiple separate bus bars, each carrying a subset of terminals. This segmentation reduces the terminal density on each individual bus bar, creating sufficient space between adjacent terminals for connecting thick wires while maintaining the total number of terminals needed for the increased number of coils and teeth.
2Reliability
If the number of teeth on the stator is increased to reduce vibration, then smooth steering is achieved, but the number of terminals on the bus bar doubles requiring twice as many wire connections
Solution Approach 1:
The bus bar structure is segmented into multiple separate bus bars, each handling a portion of the terminal connections. This reduces the complexity of wire connections on each individual bus bar by decreasing terminal density, while the collective system maintains the total number of terminals required for the increased number of teeth.
Solution Approach 2:
The invention redistributes terminals across multiple bus bars in the spatial dimension, transforming the connection architecture from a single dense bus bar to a distributed multi-bus bar system. This dimensional change in the connection structure reduces local terminal density while preserving the overall terminal count.
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 configuration reduces terminal density, improves wire connection accessibility, and maintains high reliability by allowing greater spacing between terminals, facilitating easier connection and operation of the motor.
Implementation Method 1
A plurality of insulators cover at least a portion of the stator core to insulate the portion of the stator core
Implementation Method 2
Each of a plurality of coils is defined by a multilayer structure of a wire wound around each of the tooth portions via the insulator
Implementation Method 3
a brushless motor having a stator on which an insulator is arranged
Data Source
AI summary
A motor includes a stator including a core back having a circular or substantially circular shape, a plurality of tooth portions extending radially inwardly from the core back, a plurality of insulators covering the tooth portions, a plurality of coils formed by winding wires around the tooth portions via the insulators. The motor also includes a bus bar arranged axially above the stator. The bus bar supports a first conductor plate having a plurality of first terminals to which first end portions of the wires from each phases of the coils are connected. The insulators include a guiding groove and support therein the second conductor plate to which second end portions of the wires are connected. Through the second conductor plate, the second end portions of the wires are connected to the neutral point.