Busbar Base Plate for Precise Stator Lead Alignment
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Solution Overview
Problem
Existing electric machines face challenges in ensuring proper alignment and protection of stator leads during the assembly of busbar assemblies, which can lead to damage and compromise the stator's performance.
Innovation Solution
The introduction of an alignment plate that interposes between the stator and busbar assembly, providing a rigid base with openings and alignment features to ensure precise alignment and protect the stator leads during welding, minimizing movement and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar assembly is assembled directly to the stator leads without an alignment plate, then the assembly process is simpler and fewer parts are used, but the stator leads are vulnerable to misalignment and damage during welding
Solution Approach 1:
The alignment plate serves as an intermediary component between the busbar assembly and the stator leads. It provides a rigid base with precisely positioned openings that guide the stator leads through them, ensuring proper alignment during welding while protecting the leads from damage. The plate mediates the connection process by holding the busbar body and aligning it with the leads extending from the stator core.
2Manufacturing precision
If the stator leads are routed directly over the end turns without an alignment plate, then the space utilization is more efficient and the structure is simpler, but the alignment precision and protection of leads are compromised
Solution Approach 1:
The alignment plate is prepared in advance with precisely positioned openings that correspond to the locations of the stator leads. The plate is then placed over the end turns before the busbar assembly is attached, preliminarily establishing the correct alignment positions for all leads. This preliminary positioning ensures that when the busbar is welded to the leads, the alignment is already established and precise.
3Reliability
If a rigid alignment plate is used to ensure precise alignment and protection, then the manufacturing precision and reliability improve, but the device complexity and number of parts increase
Solution Approach 1:
The alignment plate performs multiple functions simultaneously: it serves as a alignment guide with precisely positioned openings for the stator leads, provides a rigid base for mounting the busbar assembly, protects the leads during the welding process, and maintains the spatial relationship between the busbar and stator core. By consolidating these multiple functions into a single component, the design improves reliability without adding excessive complexity.
Data Source
AI summary
A stator assembly of an electric machine includes of stator leads extending outward from one end of the stator core. A busbar assembly includes a busbar body supporting a plurality of lead connectors that are connected to corresponding stator leads. An alignment plate is interposed between the stator assembly and the busbar assembly. The alignment plate includes a rigid base plate having a planar bottom face supported on the top surface of the end turns and an opposite top face supporting the busbar body. The base plate defines a plurality of openings corresponding to the plurality of stator leads and arranged to be aligned with the stator leads. One or more of the stator leads extends through a corresponding one of the plurality of openings. Each of the openings is sized and configured for a close running fit with the stator lead or leads extending therethrough.