Flexible Busbar Assembly for Stator Manufacturing
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Solution Overview
Problem
Current manufacturing methods for stator assemblies in electric machines are inefficient and prone to errors, especially when dealing with a large number of windings, due to the rigidity of busbar assemblies, which can lead to misalignment and damage to the windings during assembly.
Innovation Solution
A method involving the flexible arrangement of busbars in a busbar assembly, allowing for easier alignment and connection to conductive terminals, reducing the force required for assembly and enhancing the reliability of the stator assembly by using a flexible busbar assembly with adjustable curvature and layers, and potentially incorporating low-friction materials and adhesives for relative movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid busbars are used in the busbar assembly, then structural strength and stability are improved, but alignment difficulty and risk of damage to windings increase during assembly
Solution Approach 1:
The busbar assembly is designed to be flexible rather than rigid, allowing it to adapt its shape during assembly to match the positions of conductive terminals. This dynamic flexibility resolves the contradiction by enabling easy alignment while maintaining structural integrity through the busbar's inherent strength properties.
Solution Approach 2:
The patent changes the physical state parameter of the busbar assembly from rigid to flexible. This parameter change allows the assembly to deform and conform to terminal positions during assembly, solving the alignment difficulty while the busbar's design maintains sufficient structural strength for electrical connection.
2Stability of the object's composition
If rigid busbars are used in the busbar assembly, then structural stability is improved, but manufacturing time and error rate increase due to alignment difficulties
Solution Approach 1:
The flexible busbar assembly can dynamically adjust its configuration during assembly operations, eliminating time-consuming alignment adjustments and reducing errors. This improves manufacturing efficiency while the busbar's design ensures structural stability is maintained for reliable electrical connections.
Solution Approach 2:
The busbar assembly is designed with inherent flexibility that allows it to automatically conform to terminal positions during assembly, eliminating the need for preliminary alignment adjustments or positioning operations, thus improving manufacturing efficiency.
3Strength
If high force is applied during busbar assembly, then connection strength is improved, but damage to stator windings increases
Solution Approach 1:
The flexible busbar assembly naturally conforms to terminal positions without requiring high assembly forces. This eliminates the harmful effect of excessive force on windings while achieving sufficient connection strength through the flexible connection mechanism.
Solution Approach 2:
The flexibility of the busbar assembly acts as a cushioning mechanism that absorbs assembly variations and misalignments, preventing the transmission of high forces to the windings while still achieving secure electrical connections.
4Manufacturing precision
If complex alignment procedures are used for rigid busbars, then positioning precision is improved, but manufacturing complexity and time increase
Solution Approach 1:
The flexible busbar assembly achieves positioning precision through its ability to adapt to terminal positions rather than through complex alignment procedures. This simplifies the assembly process and reduces manufacturing complexity while maintaining accurate electrical connections.
Data Source
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AI summary
A method of manufacturing a stator assembly (1) for an electric machine includes providing multiple stator windings (2). Each stator winding is connected to a conductive terminal (4). The method includes assembling multiple busbars (8) into a busbar assembly (10). The busbars are arranged flexibly relative to each other in the busbar assembly. The method also includes connecting the busbar assembly to some of the conductive terminals.