Modular Electric Machine Bus Bar Stator Assembly
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Solution Overview
Problem
Brushless motors using split cores require additional components and increased assembly time to maintain the annular array of split cores, leading to a higher number of components and longer assembly hours.
Innovation Solution
The use of annular plate-shaped bus bars that supply power to phase coils and maintain the annular array of split cores, simultaneously serving as a fixing mechanism, reducing the number of components and assembly time by distributing joint points on both end faces of the stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If split cores are used to allow coils to be easily wound and improve motor performance, then the space factor is increased, but additional components and assembly work are needed to maintain the annular array of split cores
Solution Approach 1:
The bus bar is designed to perform dual functions: supplying power to phase coils and maintaining the annular array of split cores. By integrating the fixing function into the power supply component, the number of separate parts is reduced while preserving the space factor benefits of split cores.
Solution Approach 2:
The bus bar serves multiple purposes simultaneously: it acts as an electrical conductor for power supply and as a structural component for maintaining the annular arrangement of split cores. This multi-functionality eliminates the need for separate fixing components.
2Quantity of substance
If split cores are used to allow coils to be easily wound and improve motor performance, then the space factor is increased, but assembly time is increased due to additional fixing work
Solution Approach 1:
The bus bar is designed to perform dual functions: supplying power to phase coils and maintaining the annular array of split cores. By integrating the fixing function into the power supply component, the number of separate parts is reduced while preserving the space factor benefits of split cores.
Solution Approach 2:
The bus bar serves multiple purposes simultaneously: it acts as an electrical conductor for power supply and as a structural component for maintaining the annular arrangement of split cores. This multi-functionality eliminates the need for separate fixing components.
3Stability of the object's composition
If separate components are used to maintain the annular array of split cores, then the array can be maintained, but the number of components and assembly complexity increase
Solution Approach 1:
The bus bar is designed to perform dual functions: supplying power to phase coils and maintaining the annular array of split cores. By integrating the fixing function into the power supply component, the number of separate parts is reduced while preserving the space factor benefits of split cores.
Solution Approach 2:
The bus bar serves multiple purposes simultaneously: it acts as an electrical conductor for power supply and as a structural component for maintaining the annular arrangement of split cores. This multi-functionality eliminates the need for separate fixing components.
Data Source
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AI summary
A rotary electric machine includes: a stator (16) including a plurality of stator pieces (24) in which phase coils are wound on teeth protruding from a each of plurality of split cores (32, 24) and which are annularly arrayed around an axis in a circumferential direction; and a rotor is disposed coaxially within the stator (16) so as to face the stator (16), wherein the stator (16) includes a plurality of annular plate-shaped bus bars (26U,26V,26W,26C) that supply power to the phase coils corresponding to the kinds of phases (U,V,W), are joined to the plurality of stator pieces (24) corresponding to the respective phases (U,V,W), and maintain an annular array of the plurality of split cores.