Busbar Holder Nesting in Electric Actuator Housing
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Solution Overview
Problem
Existing electric actuators face challenges in compact design and assembly complexity due to the difficulty in positioning and connecting the leader wire from the motor coil to the drive circuit, which complicates the fixing process and hinders size reduction.
Innovation Solution
The electric actuator design incorporates a motor portion with a motor shaft and stator, a circuit board, a speed reduction mechanism, a busbar for electrical connection, a busbar holder, and a housing that includes a compartmental wall with through-holes to accommodate the busbar holder, allowing for efficient connection and reduced size, improving assembly workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a busbar is arranged to simplify connecting work between the motor coil and drive circuit, then assembly workability is improved, but the size of the electric actuator increases
Solution Approach 1:
The busbar holder is inserted through a through-hole formed in the compartment wall of the housing, nesting the busbar connection structure within the existing housing space. This allows the busbar to be properly positioned and connected without adding external volume to the actuator, while still providing simplified assembly compared to leader wire routing.
2Ease of manufacture
If a busbar is used to electrically connect the motor and drive circuit, then connecting work is simplified, but the device complexity increases due to additional components
Solution Approach 1:
The compartment wall serves multiple functions: it provides structural separation between the motor and drive circuit compartments, and simultaneously incorporates a through-hole that facilitates busbar installation. This multi-functionality reduces the need for separate dedicated busbar mounting structures, thereby simplifying the overall device complexity while maintaining ease of connection.
3Reliability
If the leader wire is extended from the motor coil to the drive circuit, then electrical connection is achieved, but positioning difficulty and fixing complexity increase
Solution Approach 1:
The busbar acts as an intermediary component between the motor coil and drive circuit. Instead of directly routing and fixing the flexible leader wire from the coil to the circuit board, the rigid busbar provides a stable, easily positionable connection medium that can be securely mounted via the busbar holder, thereby maintaining reliable electrical connection while dramatically reducing fixing complexity.
Data Source
AI summary
An electric actuator includes a motor portion, a circuit board, a speed reduction mechanism, a busbar holder that holds a busbar, and a housing. The housing has a motor case and a compartmental wall. The compartmental wall has a through-hole which penetrates the compartmental wall in an axial direction. The busbar holder has a base portion and a projecting portion which projects from the base portion in the axial direction and is disposed in the through-hole. An end portion of the busbar at one side projects from the busbar holder toward one side in the axial direction and is connected to the circuit board, and an end portion of the busbar at the other side projects into the through-hole from a side surface of the projecting portion of the busbar holder and is connected to a coil of a stator.