Insulator Holding Structure for Electric Motor Bus Rings

Solution Overview

Problem

The existing electric motor designs require costly molding processes for fixing members, increasing production costs due to the need for resin injection and mold fabrication.

Innovation Solution

An electrical collecting and distributing member holding structure that incorporates recesses on the insulator for press-fitting the bus rings, eliminating the need for molding and using U-shaped conductors with extended portions for secure electrical connections to the windings, reducing assembly complexity and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fixing members are molded using resin injection process, then the electrical collecting and distributing members can be securely fixed, but the production cost increases due to mold fabrication and molding process

Engineering Contradiction:

Improvefixing strengthVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention extracts and eliminates the separate fixing members from the structure. Instead of using distinct fixing components that require molding, the holding portions are directly formed as integral parts of the insulator through machining or forming processes, thereby removing the need for separate fixing member production and assembly

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the function of fixing members into the insulator itself. The holding portions are integrated directly into the insulator structure, combining the insulator and fixing functions into a single component, which eliminates the need for separate fixing members and reduces production complexity

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If multiple separate fixing members are used to hold bus rings, then secure fixation is achieved, but the device complexity and assembly difficulty increase

Engineering Contradiction:

Improvefixation securityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the separate fixing members from the structure. Instead of using distinct fixing components that require molding, the holding portions are directly formed as integral parts of the insulator through machining or forming processes, thereby removing the need for separate fixing member production and assembly

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the function of fixing members into the insulator itself. The holding portions are integrated directly into the insulator structure, combining the insulator and fixing functions into a single component, which eliminates the need for separate fixing members and reduces production complexity

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If molding process is used for fixing members, then fixation is achieved, but the production time and manufacturing complexity increase

Engineering Contradiction:

Improvefixation strengthVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention extracts and eliminates the separate fixing members from the structure. Instead of using distinct fixing components that require molding, the holding portions are directly formed as integral parts of the insulator through machining or forming processes, thereby removing the need for separate fixing member production and assembly

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The holding portions are pre-formed as integral parts of the insulator during insulator manufacturing, before the bus rings are installed. This preliminary formation of holding portions eliminates the need for subsequent molding operations and fixing member assembly, streamlining the production process

Inventive Principle:

Principle #10Preliminary action

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 approach lowers production costs by eliminating the need for resin molding and simplifies assembly, while ensuring secure electrical connections and reduced axial dimensions, enhancing the motor's efficiency and reliability.

Implementation Method 1

an insulator for electrical insulation between the cores and the windings

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

a holding portion formed on the insulator, the holding portion including a plurality of recesses formed therein, the plurality of electrical collecting and distributing members being held in the holding portion in such a manner as to be partially received in the plurality of recesses

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Data Source

PatentUS10097069B2Electrical collecting and distributing member holding structure, electric motor, and electric motor producing method

Publication Date: 2018.10.09 PROTERIAL LTD

AI summary

An electrical collecting and distributing member holding structure is composed of a stator including a multiplicity of cores arranged annularly, windings wound around the multiplicity of cores respectively, and an insulator for electrical insulation between the cores and the windings, a plurality of annular electrical collecting and distributing members held around the stator to collect and distribute electric current to the windings, and a holding portion formed on the insulator. The holding portion includes a plurality of recesses formed therein. The plurality of electrical collecting and distributing members are being held in the holding portion in such a manner as to be partially received in the plurality of recesses, respectively.