Motor Power Supply Busbar Plug Assembly for Vibration Resistance
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Solution Overview
Problem
Existing electric motor power supply devices in electric vehicles are prone to damage due to loose or broken welded connections from mechanical vibrations, posing a risk to the electrical connection integrity.
Innovation Solution
An integrated electrical connection unit with a busbar arrangement and insulating plug is used, allowing external connection to the motor without welding, featuring a busbar assembly overmolded with plastic and secured by a flange section to the housing, ensuring mechanical stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welded connections are used to connect busbars to connection plates in the housing, then electrical connection is achieved, but the connection becomes vulnerable to loosening and breaking due to vibrations during motor operation
Solution Approach 1:
The patent replaces the welded mechanical connection system with a plug connection system. The busbars are led out of the housing through a plug that can be connected to external electrical lines without welding. This substitution eliminates the vulnerability of welded joints to vibration-induced loosening and breaking, while maintaining electrical conductivity.
Solution Approach 2:
The plug serves as an intermediary component between the busbars inside the housing and the external electrical lines. It provides a vibration-resistant connection interface that mediates the electrical connection without requiring direct welded attachment of busbars to connection plates, thus protecting against vibration damage.
2Ease of manufacture
If welded connections are used for electrical power supply, then electrical conductivity is established, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent segments the electrical connection system into modular components: busbars inside the housing, a plug as an interface component, and external electrical lines. This segmentation allows each component to be prepared separately and assembled through simple connection operations, eliminating the need for complex welding procedures and reducing assembly time.
Solution Approach 2:
By replacing the welding process with a plug connection system, the patent eliminates time-consuming welding operations. The plug can be quickly attached to the busbars and connected to external lines through simple mechanical or electrical connectors, significantly reducing assembly time and simplifying the manufacturing process.
Data Source
AI summary
An electric power supply device for an electric motor is disclosed. The device includes a housing including a pot base and a pot collar projecting at an angle from the pot base. An electrical connection unit is arranged in a housing interior that includes a busbar arrangement with at least three busbars for an electrical power supply. The connection unit includes an electrically insulating plug via which the busbars are electrically led out of the housing interior. The plug is arranged at least partially in a lead-through opening disposed on the pot collar and has a plug housing, in which the respective end portions of the busbars are arranged. The plug merges into a flange section that fixes the connection unit on the pot base.