Busbar Holder Foot Layout for Stable Motor Assembly
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Solution Overview
Problem
The existing busbar holder in motors is prone to skewing and instability due to unequal foot lengths, leading to potential damage and misalignment during assembly and operation.
Innovation Solution
A busbar holder design with at least one shorter foot positioned axially below an axial force receiver, supported by a stator core, and other feet inserted into an insulator, ensuring stable support and preventing misalignment and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If all feet of the busbar holder are made of equal length, then the structure is simple and easy to manufacture, but the busbar holder becomes unstable and prone to skewing and displacement during assembly
Solution Approach 1:
The patent applies asymmetry by making the feet of the busbar holder unequal in length. Specifically, at least one foot has a different length from the other feet, creating an asymmetric structure that prevents skewing and displacement while maintaining manufacturing simplicity. This asymmetric design allows the busbar holder to be stably positioned on the stator core without requiring complex manufacturing processes.
2Strength
If the feet supporting the power terminals are made longer, then the power terminals are better supported, but the busbar holder becomes skewed and displaced causing instability
Solution Approach 1:
The patent applies local quality by differentiating the function and dimensions of individual feet. At least one foot is designed with a different length to specifically support the power terminals axially, while other feet are positioned to provide circumferential positioning and overall stability. This localized differentiation allows each foot to perform its specific function optimally without causing skewing or displacement.
3Ease of manufacture
If the busbar holder structure is simplified with equal-length feet, then manufacturing is easier, but the positioning accuracy and alignment of the busbar holder deteriorates
Solution Approach 1:
The patent uses asymmetry in foot length to achieve precise positioning and alignment of the busbar holder. By making at least one foot different in length from the others, the design ensures accurate circumferential positioning and axial alignment without requiring complex manufacturing processes or additional positioning mechanisms, thus maintaining ease of manufacture while improving positioning accuracy.
Data Source
AI summary
Disclosed is a busbar holder for a motor and a motor. The busbar holder includes a main body in an annular or substantially annular shape and a plurality of feet extending downwards along the main body. The main body has an axial force receiver that receives force in an axial direction. At least one foot among the plurality of feet is positioned axially below the axial force receiver, a height of the at least one foot in the axial direction is less than heights of other feet among the plurality of feet in the axial direction, and the other feet are supported by a stator core of the motor. The busbar holder is thus reliably supported, and the busbar holder is prevented from being damaged when the axial force receiver is subjected to axial pressure.