Flexible Busbar Connector Assembly for Stator Tolerance Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical machines with busbar devices face challenges in maintaining reliable electrical connections in wet and humid environments, complicating manufacture and assembly due to stringent tolerances required for the busbar and control device alignment.
Innovation Solution
A busbar device carrier is attached to the stator at an attachment section with a detachable connector section, allowing the connector to move relative to the stator for simplified assembly and reliable electrical connection, using a plug-in mechanism with male and female connectors, and a flexible, elastic connector section to accommodate manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar device and control device are manufactured with stringent tolerances to ensure reliable electrical connection, then the electrical connection reliability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The connector section is designed to be flexible rather than rigid, allowing it to dynamically adjust its position to compensate for manufacturing tolerances. The flexible connector section can bend or deform to maintain proper electrical contact between the busbar device and control device, eliminating the need for stringent tolerance requirements while preserving connection reliability.
Solution Approach 2:
The invention changes the physical state of the connector section from rigid to flexible, allowing it to adapt to dimensional variations. This parameter change enables the system to accommodate manufacturing tolerances without compromising the electrical connection reliability.
2Ease of manufacture
If the busbar device and control device are manufactured with greater tolerances to simplify manufacturing, then the ease of manufacture is improved, but the electrical connection reliability deteriorates
Solution Approach 1:
The flexible connector section provides dynamic adaptation to dimensional variations, allowing the system to maintain reliable electrical connections even when components are manufactured with larger tolerances. This enables simpler, more cost-effective manufacturing processes while preserving connection reliability.
Solution Approach 2:
By changing the connector section from rigid to flexible, the system can accommodate greater manufacturing tolerances without sacrificing electrical connection reliability, thereby simplifying the manufacturing process.
3Stability of the object's composition
If the connector is fixed rigidly to the stator to ensure stable electrical connection, then the electrical connection stability is improved, but the assembly complexity increases due to alignment requirements
Solution Approach 1:
The flexible connector section acts as a compliant element that absorbs misalignment between the busbar device and control device during assembly. This dynamic flexibility simplifies the assembly process by eliminating the need for precise alignment while maintaining stable electrical connections during operation.
Solution Approach 2:
The flexible connector section serves as an intermediary element between the rigid busbar device and control device, accommodating dimensional variations and misalignments. This mediator allows both components to be assembled with simpler fixtures and less precise alignment while maintaining stable electrical connections.
4Ease of operation
If the connector section is made flexible to accommodate tolerances and simplify assembly, then the ease of assembly is improved, but the structural rigidity decreases
Solution Approach 1:
The carrier is designed with non-uniform properties: the attachment section remains rigid for secure mounting to the stator, while the connector section is made flexible for easy assembly and tolerance accommodation. This local differentiation of rigidity allows the structure to achieve both assembly ease and adequate electrical connection stability.
Solution Approach 2:
The carrier is segmented into functionally distinct regions: a rigid attachment section for secure mounting and a flexible connector section for tolerance accommodation. This segmentation allows each section to optimize its mechanical properties for its specific function, achieving both assembly ease and connection stability.
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 design simplifies the manufacture and assembly of electrical machines by allowing greater tolerance in component alignment while maintaining a reliable electrical connection, suitable for use in humid environments.
Implementation Method 1
the connector section (30) is formed of a flexible, in particular of an elastic substance or material
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to an electrical machine (1), in particular a compressor (4) for an air-conditioning installation (2), which comprises a stator (15) and a busbar device (17) for the electrical connection of the stator (15) to a control device (16). The busbar device (17) comprises a carrier (18), which is arranged on an end face of the stator (15), and a connector (36) which projects from the carrier (18). A simplified manufacture and assembly, with a simultaneously reliable electrical connection between the connector (36) and the control device (16), are achieved wherein the carrier (18) comprises a attachment section (29) which is attached to the stator (15) and a connector section (30) which is detached from the stator (15), wherein the connector arranged on the connector section (30).