Motor Bus Bar Nesting for Axial Miniaturization
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Solution Overview
Problem
Conventional motors with multiple bus bars for three-phase circuits face complexity and increased axial dimensions due to overlapping bus bars, making them bulky and difficult to arrange effectively.
Innovation Solution
A three-phase brushless motor design with a Δ connection using six or more poles, featuring a unique configuration of first, second, and third bus bars with specific connecting portions that allow for side-by-side arrangement without overlapping, reducing axial dimensions and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple bus bars are used for three-phase circuits of multiple systems, then the motor can achieve higher power and multi-system functionality, but the arrangement of bus bars becomes complicated and the axial dimension increases
Solution Approach 1:
The patent applies nesting by placing the first, second, and third bus bars in an overlapping axial arrangement where they nest within the same radial space. The bus bars are positioned at different axial locations (first bus bar at first axial position, second bus bar at second axial position, third bus bar at third axial position) allowing multiple bus bars to occupy the same radial envelope without increasing the overall axial dimension significantly.
Solution Approach 2:
The patent transitions from a planar arrangement to a three-dimensional arrangement by utilizing the axial dimension more efficiently. Instead of arranging bus bars side-by-side in the radial direction (which would increase radial dimension), the invention arranges them along the axial direction with overlapping radial projections, effectively using the axial dimension to accommodate multiple bus bars without proportionally increasing the overall motor axial length.
2Power
If multiple bus bars are used for three-phase circuits of multiple systems, then the motor can achieve higher power and multi-system functionality, but the arrangement of bus bars becomes complicated
Solution Approach 1:
The patent segments the bus bar system into three distinct bus bars (first, second, and third bus bars), each with specific connecting portions assigned to particular phases. The first bus bar has first and second connecting portions for first and second phases, the second bus bar has a third connecting portion for the third phase, and the third bus bar has a fourth connecting portion for the first phase. This segmentation allows for systematic organization and simplifies the arrangement compared to a monolithic bus bar structure.
Solution Approach 2:
The patent applies local quality by assigning specific functions to specific portions of the bus bars. Each bus bar has specific connecting portions at defined axial and radial positions, with each connecting portion dedicated to a specific phase connection. This localized functional assignment simplifies the overall arrangement by creating a systematic pattern rather than requiring complex custom arrangements for each connection point.
3Adaptability or versatility
If bus bars are arranged to accommodate multiple three-phase circuits, then multi-system functionality is achieved, but the bus bars overlap in axial direction increasing motor size
Solution Approach 1:
The patent applies nesting by arranging the bus bars such that their radial projections overlap while positioning them at different axial locations. The first bus bar is at a first axial position, the second bus bar is at a second axial position, and the third bus bar is at a third axial position, allowing them to nest within the same radial space without requiring proportional increases in axial dimension.
Data Source
AI summary
A motor includes a stator including, a rotor to rotate about a central axis extending in a vertical direction, and a first bus bar, a second bus bar, and a third bus bar to which lead wires of the coils are respectively connected. The first bus bar includes a first connecting portion to which two lead wires are connected, the second bus bar includes a second connecting portion to which two lead wires are connected, the third bus bar includes a third connecting portion to which one lead wire is connected and a fourth connecting portion to which one lead wire is connected. The first and second connecting portions are arranged side by side in a circumferential direction, and the third and fourth connecting portions are arranged in the circumferential direction with the first and second connecting portions interposed therebetween.