Hairpin Winding Terminal Block Layout for Low-Resistance Connection
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Solution Overview
Problem
Existing electric machines in hybrid and electric vehicles face challenges in efficiently connecting hairpin windings to terminal blocks, which can lead to increased resistance and reduced efficiency due to complex wiring configurations and lack of effective insulation and cooling mechanisms.
Innovation Solution
The implementation of a terminal block with insulating material encapsulating bus bars and neutral bars, featuring ports and slots for lead and neutral ends, along with flexible joints and cooling channels, enhances connectivity and reduces electrical resistance while providing efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex wiring configurations are used to connect hairpin windings to terminal blocks, then connectivity is achieved, but electrical resistance increases and efficiency decreases
Solution Approach 1:
The terminal block is segmented into multiple individual connection points (bus bars) that directly interface with each parallel electrical path. This segmentation eliminates the need for complex interconnecting wiring between windings and terminals, as each hairpin winding connects directly to its corresponding bus bar through the insulating material's integrated ports, thereby reducing electrical resistance and energy loss.
Solution Approach 2:
The insulating material encapsulates the bus bars and neutral bars within its structure, with ports and receiving orifices nested directly into the insulating material itself. This nesting integrates the connection pathways within the insulating material, eliminating external wiring and reducing the number of connection interfaces, thus lowering electrical resistance while maintaining reliable connectivity.
2Ease of manufacture
If traditional terminal block designs are used, then manufacturing is simpler, but insulation effectiveness and cooling capability are insufficient
Solution Approach 1:
The terminal block employs a composite structure where conductive bus bars and neutral bars are encapsulated within an insulating material. This composite design integrates both conductive and insulating properties into a single unified component, ensuring effective insulation while maintaining electrical connectivity. The insulating material is molded to include integrated ports and receiving orifices, combining insulation, connection, and structural functions in one manufacturable part.
3Device complexity
If traditional terminal block designs are used, then device complexity is lower, but cooling capability and heat dissipation are inadequate
Solution Approach 1:
The insulating material incorporates a porous or channelled structure with integrated cooling channels that allow coolant flow through the terminal block. These channels are formed within the insulating material itself during molding, creating a heat dissipation pathway without adding separate cooling components. The porous structure increases surface area for heat transfer while maintaining the insulating properties, enabling effective cooling without increasing device complexity.
Data Source
AI summary
An electric machine includes windings, a terminal block, and terminal connectors. The windings have lead ends and neutral ends. The terminal block has a plurality of bus bars, a neutral bar, and an insulating material. Each bus bar is connected to one or more of the lead ends. The neutral bar is connected to one or more of the neutral ends. The insulating material encapsulates the plurality of bus bars and the neutral bar, defines a plurality of orifices, and defines a plurality of slots. Each lead end extends through one of the orifices from the outer boundary to one of the bus bars. Each neutral end extends through one of the orifices from the outer boundary to neutral bar. Each terminal connector extends through one of the slots from the outer boundary to one of the bus bars.