Integral Busbar Terminals for Compact Electric Motor Connections
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Solution Overview
Problem
Conventional electric motors with busbars as relay members require additional connecting members and output terminal blocks, leading to a complex connection system, increased parts, and compromised lightness and compactness.
Innovation Solution
Integrally forming busbars with driving circuit connecting terminals that directly connect to an external driving circuit, eliminating the need for separate connecting members and output terminal blocks, and configuring the terminals as flat plates for surface contact with a driving circuit board, which is vertically disposed at the end of an insulator to enhance compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connecting members (internal terminals and three-phase circuit output bolts) are used to connect busbars to external driving circuit, then reliable electrical connection is achieved, but device complexity increases and number of parts increases
Solution Approach 1:
The busbar and driving circuit connecting terminal are integrated into a single integral structure. The terminal is formed as an extension of the busbar itself, eliminating the need for separate internal terminals and output bolts. This merging of components simplifies the connection system while maintaining reliable electrical connection between the coils and external driving circuit.
2Reliability
If separate connecting members and output terminal blocks are used, then reliable electrical connection is achieved, but weight increases and compactness is compromised
Solution Approach 1:
By integrating the driving circuit connecting terminal directly onto the busbar structure, the patent eliminates redundant components such as separate internal terminals, output terminal blocks, and multiple bolts. This reduction in component count directly decreases the overall weight of the motor while preserving reliable electrical connection.
3Reliability
If separate connecting members and output terminal blocks are used, then reliable electrical connection is achieved, but device complexity increases and space occupation increases
Solution Approach 1:
The integral structure of the busbar with built-in connecting terminals eliminates the need for separate output terminal blocks and their associated harness slots. This merging of functions into a single component reduces the space required for electrical connections, thereby decreasing the overall volume of the motor while maintaining connection reliability.
4Reliability
If multiple separate connecting members are used, then reliable electrical connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The busbar and driving circuit connecting terminal are manufactured as a single integral component, which can be produced in one piece using processes such as stamping, extrusion, or injection molding. This eliminates the need for separate manufacturing of internal terminals, output bolts, and terminal blocks, followed by multiple assembly steps. The integral structure simplifies manufacturing while ensuring reliable electrical connection.
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
Simplifies the connection system from coils to the external driving circuit, reduces the number of parts, and achieves greater lightness and compactness by eliminating unnecessary connecting members and terminal blocks, while ensuring positive electrical contact and reduced axial length.
Implementation Method 1
coils of a plurality of phases, which are wound around the stator core and rotates a rotor by an electromagnetic force
Implementation Method 2
a plurality of busbars that are fixed to the insulator, and relay feed of power to the coils
Data Source
AI summary
The invention provides an electric motor including a tubular insulator that insulates coils of each of U, V, and W phases that makes a rotor rotated by an electromagnetic force, and a stator core around which the coils are wound; and a plurality of busbars that are fixed to the insulator to relay feed of power to the coils that constitute each phase. Ring-shaped terminals directly connected to an external driving circuit board for controlling a driving current leading to each phase of the coils, without via separate connecting members, are integrally formed in the busbars, respectively.