Circular Bus-Bar Assembly for Brushless DC Motor
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Solution Overview
Problem
Existing bus-bar structures for 3-phase brushless DC motors complicate assembly and reduce workability due to the need for individual coil connections to bus-bars, leading to decreased productivity.
Innovation Solution
A bus-bar assembly with a circular bus-bar and contact portions electrically connected to coils, housed within a bus-bar assembly that is coupled to a stator core's upper insulator, facilitating easier assembly and electrical connections through a PCB housing and shaft integration, with secure connections via fusing welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual coil connections are made to bus-bar connecting terminals, then electrical connection is achieved, but workability is deteriorated and assembly becomes difficult
Solution Approach 1:
The patent merges multiple separate bus-bars into a single integrated circular bus structure with multiple contact portions. This consolidation eliminates the need for individual connections to separate bus-bars, as coils can be connected to the circular bus in a continuous winding manner, significantly improving workability while maintaining reliable electrical connections.
Solution Approach 2:
The circular bus is segmented into multiple contact portions that are spatially distributed around the circular structure. This segmentation allows coils to be connected sequentially to different contact portions during the winding process, enabling easy access and connection while maintaining the integrated structure that improves workability.
2Reliability
If individual coil connections are made to bus-bar connecting terminals, then electrical connection is achieved, but productivity is reduced
Solution Approach 1:
By merging multiple bus-bars into a single circular bus structure, the patent enables continuous coil winding and connection processes. The circular geometry allows coils to be wound and connected sequentially without requiring repositioning or complex alignment operations, thereby increasing assembly speed and productivity while ensuring reliable electrical connections.
3Reliability
If complex power connector structure is used, then connection capability is improved, but structure complexity increases
Solution Approach 1:
The patent combines the functions of multiple separate power connectors into a single circular bus structure with multiple contact portions. This integrated design simplifies the overall structure by eliminating the need for multiple separate connectors while maintaining the capability to connect multiple coils, thereby reducing structural complexity without compromising connection capability.
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
The new bus-bar assembly design enhances workability and productivity by simplifying the assembly process and ensuring reliable electrical connections, reducing the complexity and time required for motor assembly.
Implementation Method 1
the contact portion and the coil may be further secured to each other by fusing welding
Data Source
AI summary
Disclose herein is a motor. The motor includes a stator assembly that has a stator core, an upper insulator covering and insulating an upper portion of the stator core, and a lower insulator covering and insulating a lower portion of the stator core, and a bus-bar assembly that has a bus-bar having a plurality of connecting terminals formed on a circular bus and a contact portion electrically connected to a coil, and a bus-bar housing accommodating the bus-bar therein. The bus-bar housing is coupled to a bus-bar seat defined in a central portion of the upper insulator.