Segmented Bus Bar Insulation for Compact Electric Machine Units
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Solution Overview
Problem
The existing bus bar units in electric machines are large due to overlapping conductive bars and extensive insulation, which increases the size of the unit and complicates the structure.
Innovation Solution
A bus bar unit production method involving conductive bars with connecting and insulation portions, where insulation is provided on the surface of the insulation portions and connected through the insulation to form bus bars, reducing the size while maintaining electrical insulation, and using a resin material for cost-effectiveness and improved cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive bars are overlapped and accommodated by one insulation, then electrical insulation is achieved, but the size of the bus bar unit increases
Solution Approach 1:
The patent divides the insulation function into multiple segments: each conductive bar has its own insulation portion, and additional insulation is provided only at connection locations. This segmented approach maintains electrical insulation reliability while reducing the overall volume compared to a single comprehensive insulation structure.
Solution Approach 2:
The patent applies insulation locally only where electrical isolation is needed (at connection locations between conductive bars) rather than providing uniform insulation throughout. This local quality approach ensures electrical insulation at critical points while minimizing the total insulation volume and overall unit size.
2Reliability
If extensive insulation is used to accommodate overlapping conductive bars, then electrical insulation is ensured, but the structure becomes complicated
Solution Approach 1:
The insulation structure is segmented into insulation portions attached to individual conductive bars and additional insulation at connection points. This segmentation simplifies the overall structure by breaking down the complex insulation requirement into manageable, modular components that are easier to manufacture and assemble.
Solution Approach 2:
The patent transitions from a three-dimensional enclosed insulation structure to a more planar arrangement where insulation portions and connection insulation are distributed across different locations. This dimensional change simplifies the structure by eliminating the need for a single complex accommodating housing.
3Reliability
If insulation is provided on the surface of insulation portions, then electrical insulation is improved, but material usage increases
Solution Approach 1:
The patent provides insulation on the surface of insulation portions only at specific locations where electrical insulation is required (connection points between conductive bars). This local application of surface insulation improves electrical insulation reliability while minimizing material usage compared to applying insulation uniformly across all surfaces.
Solution Approach 2:
The patent applies surface insulation partially only where needed for electrical insulation rather than excessively covering all surfaces. This partial action approach ensures adequate insulation performance at critical locations while reducing overall material consumption.
Data Source
AI summary
Provided is a bus bar that is used in an electric machine. The bus bar includes a first conductive bar and a first insulation. The first conductive bar includes a first connecting portion and a first insulation portion. The first insulation is provided on a surface of the first insulation portion. The first conductive bar is connected to the second conductive bar through the first insulation and is insulated.