Motor Busbar Unit Assembly With Integrated Temperature Module
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Solution Overview
Problem
The existing busbar units for motors face complexities in assembling temperature measurement modules due to their direct mounting on stator coils, which leads to potential incorrect assembly and increased manufacturing costs due to motor-specific designs, compromising stability and reliability.
Innovation Solution
Integrating a temperature measurement module within the busbar unit, featuring an accommodation portion on the holder with an adhesive layer, fixing holes, guide protrusions, and snap-fit coupling, allowing for secure and accurate mounting regardless of stator coil structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature measurement module is mounted directly on the stator coil, then the temperature measurement function is achieved, but the assembly process becomes complicated and the reliability decreases due to potential incorrect assembly
Solution Approach 1:
The temperature measurement module is integrated into the busbar unit structure, combining two separate components (temperature measurement module and busbar) into a single unified assembly. This integration eliminates the need for separate mounting procedures and ensures proper positioning through the built-in accommodation portion and coupling mechanisms.
Solution Approach 2:
An adhesive layer is introduced as an intermediary between the temperature measurement module and the busbar unit. This adhesive layer facilitates secure mounting while accommodating slight positioning variations, and the snap-fit coupling acts as a mediator to guide proper alignment during assembly.
2Measurement precision
If the temperature measurement module is designed specifically for each motor type, then the measurement accuracy is optimized, but the manufacturing cost increases due to individual manufacturing requirements
Solution Approach 1:
The temperature measurement module is designed with a universal interface that can be applied across different motor types. The accommodation portion in the busbar unit and the snap-fit coupling mechanism provide a standardized mounting solution that maintains measurement accuracy while enabling common usage across various motor configurations.
3Productivity
If the temperature measurement module is mounted on the stator coil, then the temperature monitoring function is achieved, but the assembly process is inconvenient and time-consuming
Solution Approach 1:
By integrating the temperature measurement module into the busbar unit, the patent combines two assembly operations into one. The module is positioned and secured simultaneously with the busbar installation, eliminating separate mounting steps and reducing assembly time.
Solution Approach 2:
The accommodation portion and snap-fit coupling are pre-designed into the busbar unit structure, preparing the mounting interface in advance. This preliminary preparation eliminates the need for complex assembly procedures and ensures proper positioning automatically during installation.
4Adaptability or versatility
If the temperature measurement module uses a structure adapted to specific stator coil configurations, then the measurement accuracy is improved, but the adaptability across different motor types decreases
Solution Approach 1:
The busbar unit incorporates a universal accommodation portion design that can interface with different stator coil configurations. The snap-fit coupling mechanism provides adaptable connectivity while maintaining consistent positioning and measurement accuracy across various motor types.
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
Simplifies the assembly process, enhances the stability and reliability of the busbar unit, enables common usage of temperature measurement modules across different motor types, and improves measurement accuracy by ensuring proper alignment and contact.
Implementation Method 1
an adhesive layer, fixing holes, guide protrusions, and snap-fit coupling, allowing for secure and accurate mounting
Data Source
AI summary
The present disclosure relates to a busbar unit for a motor, which includes: a terminal; a holder configured to support the terminal and having an accommodation portion disposed in an outer surface of the holder; and a temperature measurement module disposed in the accommodation portion, thereby simplifying a structure of the busbar unit and a process of assembling the busbar unit and improving stability and reliability of the busbar unit.