Annular Bus Ring Crimped Lead-Out Wire Inserting Portion
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Solution Overview
Problem
Conventional centralized power distribution members for electric motors require increased man-hours and components due to the need for connecting terminals and soldering, which complicates the connection process.
Innovation Solution
The use of crimped lead-out wire inserting portions on annular bus rings made of metal conductors, eliminating the need for connecting terminals and soldering by directly connecting the lead-out wires to the bus rings, thereby reducing the number of components and man-hours required for connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connecting terminals and soldering are used to connect lead-out wires to bus rings, then reliable electrical connection is achieved, but the number of components and man-hours required for connection increase
Solution Approach 1:
The patent merges the connecting terminal and the bus ring into a single integrated structure. The lead-out wire inserting portion is formed directly from the bus ring material, eliminating the need for separate connecting terminals. This integration reduces the number of components while maintaining reliable electrical connection through direct crimping of the lead-out wire to the bus ring.
Solution Approach 2:
The patent extracts and eliminates the connecting terminal from the connection system. By forming the lead-out wire inserting portion directly on the bus ring, the separate connecting terminal component is removed entirely, simplifying the overall structure while preserving the essential connection function.
2Reliability
If connecting terminals and soldering are used to connect lead-out wires to bus rings, then reliable electrical connection is achieved, but man-hours required for connection increase
Solution Approach 1:
By integrating the lead-out wire inserting portion into the bus ring structure, the patent reduces the connection process to a single crimping step. This eliminates the need for separate terminal attachment and soldering operations, significantly reducing man-hours while maintaining connection reliability through the direct crimp connection.
Solution Approach 2:
The patent replaces the soldering process (thermal/chemical joining) with a mechanical crimping process. The lead-out wire inserting portion is crimped onto the lead-out wire, providing reliable electrical connection without requiring soldering operations, thereby reducing connection time and complexity.
3Reliability
If multiple connecting steps are used to connect lead-out wires to bus rings, then secure connection is achieved, but productivity decreases
Solution Approach 1:
The patent combines multiple connection steps into a single crimping operation. The integrated lead-out wire inserting portion allows the lead-out wire to be directly crimped to the bus ring in one step, eliminating the need for separate terminal attachment and soldering steps, thereby improving productivity while maintaining connection security.
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 solution simplifies the connection process, reduces electrical resistance, and provides a more secure join between the bus rings and windings, while minimizing the use of additional conductive members.
Implementation Method 1
the lead-out wire inserting portion is crimped with the lead-out wire inserted therethrough such that the metal conductor is electrically connected to the lead-out wire
Implementation Method 2
it is necessary to temporarily fix the bent portions of the frame part to the coil of the stator and to further carry out soldering
Implementation Method 3
The winding of stator sandwiched and temporarily fixed between the pair of bent portions is soldered, thereby connecting the frame parts to the winding of the stator
Data Source
AI summary
An electric motor includes a stator including multiple phase windings wound around a plurality of teeth arranged in a circular pattern, and an annular bus ring arranged concentrically with the stator to supply drive current to the windings. The bus ring includes a metal conductor and a lead-out wire inserting portion for inserting a lead-out wire of the winding therethrough, the lead-out wire inserting portion being formed by bending the metal conductor. The lead-out wire inserting portion is crimped with the lead-out wire inserted therethrough such that the metal conductor is electrically connected to the lead-out wire.