Motor Bus Bar Structure for Coil-to-Terminal Connection
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Solution Overview
Problem
The existing motor manufacturing process becomes complex and costly due to the need for additional bus bars with specific cross-sectional shapes to connect coils with external devices, especially when the external device terminals are not bar-type.
Innovation Solution
A motor design that uses a single bus bar with a body connected to the coil and an extension part with differing cross-sectional shapes to connect with both the coil and the external device, supported by a bus bar holder with corresponding holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single bus bar with varying cross-sectional shapes is used to connect both the coil and external device terminals, then the number of manufacturing processes and components is reduced, but the structural complexity of the bus bar itself increases
Solution Approach 1:
The bus bar is divided into multiple sections along its length, with each section having a different cross-sectional shape optimized for its specific function. The first section has a first cross-sectional shape for connecting to the coil, while the second section has a second cross-sectional shape for connecting to external device terminals, allowing each segment to be optimized independently while using a single continuous component
Solution Approach 2:
Different portions of the bus bar are given different local properties (cross-sectional shapes) according to their specific functional requirements. The bus bar transitions from a first cross-sectional shape at the coil connection end to a second cross-sectional shape at the external device terminal end, enabling each local region to optimize its connection characteristics
2Adaptability or versatility
If additional bus bars with specific cross-sectional shapes are used to connect coils with external devices, then the connection adaptability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The single bus bar is designed to perform multiple functions by incorporating different cross-sectional shapes along its length. It simultaneously serves as the electrical connector to the coil (with first cross-sectional shape) and as the adapter for various external device terminals (with second cross-sectional shape), eliminating the need for separate adapter components
Solution Approach 2:
The invention merges the functions of multiple separate bus bars into a single integrated component. The first section and second section of the bus bar are combined into one continuous piece that performs both the coil connection function and the external device terminal adaptation function, reducing component count and assembly complexity
Data Source
AI summary
The present invention may provide a motor comprising: a shaft; a rotor coupled to the shaft; a stator disposed to correspond to the rotor, the stator comprising a stator core, an insulator coupled to the stator core, and a coil disposed on the insulator; a bus bar electrically connected to the coil; and a bus bar holder supporting the bus bar, wherein the bus bar includes a bus bar body connected to the coil and an extension part bent from the bus bar body, the extension part includes a first part connected to the bus bar body and a second part extended from the first part, the bus bar holder includes a first hole and a second hole communicating with the first hole and having a shape that is different from that of the first hole, the shape of the cross section of the first part and the shape of the cross section of the second part are different from each other, the first part is disposed in the first hole, a portion of the second part is disposed in the second hole, and the rest of the second part is exposed to the outside of the bus bar holder.