Rotary Motor Bus Bar Layout for Shorter Terminals
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Solution Overview
Problem
Conventional bus bar terminals in rotary electric machines are excessively long, requiring a large amount of material and posing challenges in terms of material costs and assembly complexity.
Innovation Solution
The bus bar terminal is designed to be provided only in part of the circumferential direction, with lead wires extending from scattered lead-out portions to gathered connection parts, reducing the overall length and material usage, and incorporating a bus bar holder with insulating properties to ensure insulation and prevent wire entanglement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar terminal is made long to connect all lead-out portions, then electrical connection is ensured, but material cost and assembly complexity increase
Solution Approach 1:
The bus bar terminal is segmented into multiple independent connection parts rather than a single continuous structure. Each connection part corresponds to a specific lead-out portion, allowing separate connection and assembly. This segmentation reduces assembly complexity while ensuring reliable electrical connection at each point.
Solution Approach 2:
The unnecessary portions of the bus bar terminal are extracted or removed. Instead of providing a continuous bus bar terminal across the entire circumferential direction, the terminal is only provided at specific positions where lead-out portions exist, eliminating excess material and simplifying assembly.
2Reliability
If the bus bar terminal extends across the entire circumference, then all windings are connected, but material usage increases
Solution Approach 1:
The excess bus bar terminal material is extracted by limiting the terminal's presence to only those circumferential positions where lead-out portions are located. This extraction principle reduces material usage significantly while maintaining complete electrical connection coverage for all windings.
Solution Approach 2:
Instead of providing the bus bar terminal across the entire circumference (excessive action), the terminal is provided only partially at specific positions where needed. This partial action approach uses the minimum necessary material to achieve the required electrical connection function.
3Reliability
If lead wires are scattered around the circumference, then all windings are connected, but wire entanglement occurs
Solution Approach 1:
Multiple scattered lead-out portions are merged into a single gathered position where the bus bar terminal connects them. Instead of having wires scattered throughout the circumferential direction, they are all brought together at one location, eliminating entanglement while maintaining connection to all windings.
Solution Approach 2:
The connection approach transitions from a two-dimensional scattered arrangement around the circumference to a three-dimensional gathered arrangement. Lead wires extend from scattered lead-out portions in the radial direction to a gathered connection position, using the axial dimension to resolve the entanglement problem.
Data Source
AI summary
A rotary electric machine includes a bus bar holder provided on one side of a stator in an axial direction, and a plurality of bus bar terminals that electrically connect the stator and a control unit. A lead wire is drawn out to a bus bar terminal side in an axial direction from a lead-out portion located on the bus bar terminal side among a plurality of windings provided all around a circumferential direction of the stator and between a plurality of adjacent windings. The bus bar terminal includes a winding side terminal portion having at least one connection part and a board side terminal portion connected to a board. The bus bar terminals are gathered in a part in the circumferential direction. The lead wire is wired so as to extend from one of the lead-out portions scattered all around the circumferential direction to one of the connection parts.