Intersecting Bus Bar Terminal Assembly for Compact Hairpin Motors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing terminal assemblies for hairpin motors occupy a large space and have inferior insulating properties, limiting the mounting space and safety of the motor.
Innovation Solution
A terminal assembly design with a body part and intersecting bus bars, where one end section of the first bus bar extends in the width direction and the other end section of the second bus bar extends in the radial direction, with recessed and through-hole configurations to minimize space and enhance insulation, using U-shaped and straight-line fixing parts to secure and insulate the bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the terminal assembly uses a conventional design with parallel bus bars, then the structural simplicity is maintained, but the space occupied by the terminal assembly is large
Solution Approach 1:
The patent applies dimensionality change by arranging bus bars in intersecting directions (radial and width directions) rather than parallel arrangements. The first bus bar extends in the radial direction while the second bus bar extends in the width direction, creating a compact two-dimensional layout that reduces the overall volume occupied by the terminal assembly.
Solution Approach 2:
The patent implements nesting by positioning bus bars within recessed portions formed in the terminal assembly body. The recessed portions allow bus bars to be nested into the body structure rather than extending outward, effectively reducing the external dimensions and volume of the terminal assembly.
2Volume of moving object
If the terminal assembly uses a compact design with recessed portions, then the space occupied is minimized, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by forming recessed portions and through-holes in the terminal assembly body during the molding process. These features are pre-formed in the mold cavity before the actual bus bars are inserted, allowing for simplified subsequent assembly operations and reducing the need for post-processing operations.
3Reliability
If the terminal assembly uses conventional bus bar spacing, then the insulating properties are adequate, but the space required is large
Solution Approach 1:
The patent introduces an intermediary insulating structure through the terminal assembly body itself, which is formed with recessed portions that contain the bus bars. The body material acts as an insulating intermediary between bus bars extending in different directions, providing reliable electrical insulation while maintaining compact dimensions.
Data Source
AI summary
A terminal assembly includes: a body part; and a first bus bar and a second bus bar, each of which is at least partially inserted into the body part. A first end section of two opposing end sections of the first bus bar with respect to a radial direction (R) of the body part is inserted into the body part. A second end section of two opposing end sections of the second bus bar with respect to the radial direction (R) of the body part is inserted into the body part. A direction in which the first end section extends intersects with a direction in which the second end section extends.