Bus Bar Unit with U-Shaped Connectors for Motor Miniaturization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bus bar units in motors require significant radial dimensions and wire length, leading to increased complexity and material usage, which hinders miniaturization and efficiency.
Innovation Solution
A bus bar unit design featuring a bus bar holder with U-shaped lead wire connectors and linear portions that minimize radial dimensions, allowing for reduced wire usage and efficient assembly, while maintaining connectivity and stability through clamping and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are arranged on the outer side of the stator in the radial direction with concentric arrangement, then electrical connectivity is achieved, but the radial dimension increases and wire length increases
Solution Approach 1:
The bus bar configuration transitions from a conventional radial arrangement to an arrangement that utilizes the axial dimension more effectively. The bus bars are positioned to extend axially from the stator outer side, with connection portions that wrap around and connect to lead wires. This dimensional shift reduces the radial footprint while maintaining electrical connectivity through a different spatial pathway.
Solution Approach 2:
The bus bar structure is divided into distinct functional segments: a main body portion extending axially, connection portions for connecting to lead wires, and terminal portions for external connections. This segmentation allows each part to be optimized independently, with the connection portions designed to minimize radial extension while achieving reliable electrical connection to the lead wires.
2Reliability
If bus bars are arranged on the outer side of the stator in the radial direction, then electrical connectivity is achieved, but wire length increases
Solution Approach 1:
The connection path is reconfigured to utilize the axial dimension and circumferential wrapping rather than extending radially outward. The connection portions wrap around the stator periphery and connect to lead wires in a manner that shortens the overall wire length by exploiting the three-dimensional space around the stator rather than extending straight radially.
Solution Approach 2:
The connection portions of the bus bars are designed with curved paths that wrap around the stator, following the circumferential direction. This curved arrangement optimizes the wire length by utilizing the natural curvature of the stator periphery, reducing the total length required compared to straight radial extensions.
3Reliability
If conventional bus bar configuration is used, then electrical connectivity is maintained, but device complexity and material usage increase
Solution Approach 1:
The bus bar structure integrates multiple functions into a unified configuration: the main body portion serves as both a structural element and a current conductor, while the connection portions simultaneously provide mechanical support and electrical connection. This merging of functions reduces the number of separate components needed and simplifies the overall assembly process.
Solution Approach 2:
The bus bar design creates components that serve multiple purposes: the same structure provides electrical connectivity, mechanical support for lead wires, and defines the spatial arrangement of phases. This multi-functionality reduces device complexity by eliminating the need for separate structural supports and connection elements.
4Reliability
If conventional bus bar configuration is used, then electrical connectivity is maintained, but wire material usage increases
Solution Approach 1:
The wire path is redirected to travel axially and circumferentially rather than radially, utilizing the three-dimensional space around the stator more efficiently. This dimensional change shortens the wire length required to achieve the same electrical connectivity, thereby reducing material usage.
Solution Approach 2:
The connection portions follow curved paths around the stator periphery, optimizing the wire length by utilizing the circumferential geometry. This curved arrangement reduces the total wire length required compared to straight radial connections, minimizing material consumption while maintaining electrical connectivity.
Data Source
AI summary
A bus bar unit includes a bus bar holder on one side in an axial direction of an annular stator around a central axis extending in a vertical direction, a bus bar extending along a plane perpendicular to the axial direction and fixed to the bus bar holder, and an external connection terminal connected to the bus bar and extending upward from the bus bar. The bus bar includes a wire and a terminal connector located on one end thereof and connected to the external connection terminal, a first lead wire connector located on the other end thereof and connected to a lead wire extending from the stator, a second lead wire connector located between the terminal connector and the first lead wire connector, and a first linear portion to connect the first and second lead wire connectors and having a linear shape when viewed in the axial direction. Each of the first and the second lead wire connectors has a U-shape that opens in a radial direction.