ECM Stator Busbar Nesting for Torque and Resistance
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Solution Overview
Problem
Existing electronically commutated motors face challenges in achieving high torque with a compact structure while being simple and inexpensive to manufacture, particularly in applications requiring rapid startup and low internal resistance.
Innovation Solution
The design incorporates a wound laminated stator core with special busbars and a quadruple parallel delta winding scheme, featuring redundant busbars that are angularly offset and connected via resistance welding, ensuring low resistance connections and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the motor is designed to provide high torque with low internal resistance for rapid startup, then the torque and startup performance are improved, but the internal resistance and manufacturing complexity increase
Solution Approach 1:
The stator winding is divided into multiple parallel delta connections (quadruple parallel delta winding), segmenting the current path to reduce internal resistance while maintaining compact structure. This segmentation allows multiple current pathways, lowering overall resistance without increasing motor size.
Solution Approach 2:
The busbars are arranged concentrically with one another, with inner busbars nested within the structure formed by outer busbars. This nested arrangement reduces the overall footprint and internal resistance by optimizing the spatial configuration of conductive elements, allowing high torque in a compact design.
2Volume of moving object
If the motor is designed to be compact, then the volume is reduced, but the torque output and manufacturing simplicity are compromised
Solution Approach 1:
The concentric arrangement of busbars allows multiple conductive elements to be nested within each other's spatial envelope, maximizing the use of available space. This enables high torque output in a reduced volume by optimizing the density and configuration of current-carrying components.
Solution Approach 2:
The busbars are arranged in a concentric, multi-dimensional configuration rather than a linear or planar arrangement. This spatial reconfiguration allows for efficient current distribution and torque generation within a compact volume by utilizing radial and angular dimensions.
3Loss of energy
If complex interconnection parts are used to achieve low internal resistance, then the electrical performance is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
Multiple busbars are merged into a single holder structure, combining several functional elements into one integrated component. This merging simplifies manufacturing by reducing the number of separate parts that need to be assembled, while maintaining the low internal resistance through the combined conductive pathways.
Solution Approach 2:
The holder serves multiple functions: it mechanically supports the busbars, provides structural integrity to the stator assembly, and facilitates the concentric arrangement of conductive elements. This multi-functionality reduces the need for additional specialized components, lowering manufacturing complexity and cost.
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
This configuration enables high torque output with a compact structure, simplifies manufacturing, and provides low internal resistance, making it suitable for rapid startup applications while maintaining cost-effectiveness.
Implementation Method 1
The busbars are interconnected via connecting rings, which are designed as vertical busbars and arranged in a holder... featuring redundant busbars that are angularly offset and connected via resistance welding
Data Source
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AI summary
The motor has conductor rails (44(W)), (46(U)), which are insulated of each other and are switched into each other. The conductor rail (44(W)) is extended to a preset angular region (108) of a radially exterior section in the proximity of a deflecting position of the conductor rail (46(U)), which is directly adjacent to the deflecting position. Shifting of the conductor rails is mechanically limited in a peripheral direction in the angular region. The angular region is provided with connectability to a line connection running in a direction of the motor.