Busbar Holder Insulation for Rotating Electrical Devices

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Solution Overview

Problem

Existing rotating electrical devices, such as motors, face increased component count and manufacturing complexity due to the need for separate insulating members to prevent electrical contact between the busbar and bearing holder, leading to higher costs and potential insulation inconsistencies.

Innovation Solution

A rotating electrical device design that incorporates a busbar unit with an electrically insulating busbar holder, which is molded to enclose the busbars and includes an insulated terminal holding portion to ensure electrical insulation without the need for additional insulating components, thereby reducing the number of components and manufacturing steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate insulating member is added to prevent electrical contact between the busbar and bearing holder, then insulation reliability is improved, but the number of components and manufacturing complexity increase

Engineering Contradiction:

Improveinsulation reliabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating member is merged with the busbar holder to form an integrated structure. The busbar holder includes a holding portion that holds the busbar and an insulated terminal holding portion that protrudes to prevent electrical contact with the bearing holder, eliminating the need for separate insulating components while maintaining insulation reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar holder is designed to perform multiple functions: it holds the busbar, provides electrical insulation, and prevents electrical contact with the bearing holder through its insulated terminal holding portion. This multi-functional design reduces the overall number of components needed in the system

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a separate insulating member is added to prevent electrical contact, then insulation reliability is improved, but manufacturing steps and cost increase

Engineering Contradiction:

Improveinsulation reliabilityVSAvoidmanufacturing steps

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulating member is integrated into the busbar holder as a single molded part rather than a separate component. This merging reduces the number of assembly steps and manufacturing operations required, while ensuring consistent insulation performance through integral construction

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulated terminal holding portion is pre-formed as part of the busbar holder structure during molding. This preliminary formation of the insulating structure eliminates the need for subsequent assembly operations to install separate insulating members, simplifying the manufacturing process

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If the busbar passes through the bearing holder without insulation, then the structure is simpler, but electrical short circuit risk increases

Engineering Contradiction:

Improvestructural simplicityVSAvoidelectrical short circuit risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The insulated terminal holding portion of the busbar holder acts as an intermediary element between the conductive busbar and the metal bearing holder. This intermediate insulating structure prevents direct electrical contact while maintaining the simple structural arrangement of the busbar passing through the bearing holder

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If an insulating material member is added to cover the busbar passage section, then insulation is improved, but component count and assembly work increase

Engineering Contradiction:

Improveinsulation performanceVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The insulating member is combined with the busbar holder to form a single integrated component. This integration eliminates the separate assembly operation of attaching insulating members to the busbar holder, improving assembly efficiency while maintaining reliable insulation performance

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating structure is pre-integrated into the busbar holder during its formation process. This preliminary integration of the insulating function into the main component eliminates subsequent assembly steps, thereby improving productivity without compromising insulation quality

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11258330B2Rotating electrical device

Publication Date: 2022.02.22 KYB CORP

AI summary

The rotating electrical device has a motor, a bearing holder, and a busbar unit. The busbar unit has a plurality of busbars, and an electrically insulating busbar holder enclosing the plurality of busbars. The plurality of busbars are electrically connected to the plurality of coils, respectively, and inserted, on the bearing holder side of the busbar holder, through each of the plurality of terminal through-holes in the bearing holder, and the busbar holder is configured to enclose the periphery of a part where the plurality of busbars are inserted through the terminal through-holes.