Motor Busbar Terminal Structure for Lower-Scrap Coil Connection
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Solution Overview
Problem
The complex shape of terminal development figures in motor manufacturing leads to increased scrap generation and larger motor sizes due to complicated manufacturing processes and bent connection ends.
Innovation Solution
The motor design incorporates a busbar with terminals that include extension parts overlapping in the axial direction to simplify the development pattern, reducing scrap generation and motor size by combining first and second terminals with specific extension parts that contact the same end portion of the coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals with bent connection ends are used to connect coils, then the terminal can contact the coil end portions effectively, but the development figure shape becomes very complicated
Solution Approach 1:
The terminal is divided into a body portion and multiple extension parts. The extension parts are separate segments that extend from the body and contact the coil end portions, simplifying the overall development figure while maintaining effective connection capability.
2Ease of manufacture
If the development figure shape is simplified, then the manufacturing process becomes easier and scraps are reduced, but the terminal structure becomes simpler
Solution Approach 1:
The terminal structure is segmented into a body and multiple extension parts, allowing for a simpler development figure that is easier to manufacture while still providing the necessary connection points for the coils.
Solution Approach 2:
Multiple extension parts extend in different directions from the terminal body, utilizing spatial arrangement to achieve multiple connection points without increasing the complexity of the development figure.
3Ease of operation
If bent patterns of connection ends are used, then the terminal can reach coil end portions, but the length of the busbar in axial direction increases
Solution Approach 1:
Instead of bending connection ends in the axial direction, the invention uses extension parts that extend radially or in other directions from the terminal body, allowing coil end portions to be contacted without increasing the busbar's axial length.
Data Source
AI summary
The present invention may provide a motor including a shaft, a rotor coupled to the shaft, a stator disposed to correspond to the rotor, and a busbar disposed above the stator, wherein the stator includes a stator core and coils, the busbar includes a terminal connected to the coils, the terminal includes bodies and a plurality of connection ends which extend from the bodies and are in contact with end portions of the coils, a plurality of extension parts extending from the plurality of bodies are combined to constitute any one of the plurality of connection ends, and the plurality of extension parts are in contact with the same end portion of the coil.