Bus Bar Unit With Variable Width Joining Portion
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Solution Overview
Problem
The existing bus bar configurations in rotating electric machines face challenges in maintaining stable joining quality due to difficulties in positioning linear conductors during resin molding, leading to increased manufacturing complexity and susceptibility to deformation, which affects durability and requires additional parts and processes, resulting in higher costs.
Innovation Solution
A bus bar unit with bus bars of equal thickness from the external connection terminal to the joining portion, where the width of the bus bar joining portion is wider than the coil joining portion, ensuring consistent joining despite variations in position or posture, and using a bus bar integral holding portion to insulate and stabilize the bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bus bar with higher rigidity is used to simplify the joining process and improve durability, then the ease of manufacture and durability are improved, but the joining quality deteriorates when there are variations in the position and posture of bus bars during assembly
Solution Approach 1:
The bus bar is designed with non-uniform width along its length. The width at the joining portion is specifically increased to be wider than at other portions, creating a local quality variation that compensates for position and posture variations during assembly, thereby maintaining high joining quality despite using rigid bus bars that are difficult to position precisely
2Manufacturing precision
If the width of the bus bar joining portion is increased to accommodate position variations, then the joining quality is improved, but the device complexity increases
Solution Approach 1:
The width parameter of the bus bar is changed along its length, with the joining portion having a larger width than other portions. This parameter variation is designed to compensate for position and posture variations during assembly, improving joining quality without requiring complex positioning mechanisms or additional components
Data Source
AI summary
A bus bar unit includes: a plurality of bus bars which electrically connect coils of respective phases of a rotating electric machine and an external power source to each other, and integrally form external connection terminals; and a bus bar integral holding portion which covers parts of the plurality of bus bars and electrically insulates the plurality of bus bars to each other. Each bus bars is equal in thickness from the external connection terminal to a bus bar joining portion joined to a coil joining portion of each phase, and a width of the bus bar joining portion is wider than that of the coil joining portion.