Motor Busbar Insulation via Radial Cavity Overlap
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Solution Overview
Problem
Conventional motors with busbars have an increased axial dimension due to standing coil connectors, leading to a larger motor size, as they require insulation between busbars, which complicates the routing of coil ends and increases the motor's overall size.
Innovation Solution
The motor design incorporates a recessed busbar cavity in the second busbar to overlap with the upper disposed portion of the first busbar, maintaining insulation while reducing the axial dimension by allowing the busbar connectors to be positioned without extending upward, thus minimizing the motor's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil connector has a standing portion that extends upward to ensure insulation between busbars, then insulation between busbars is improved, but the axial dimension of the busbar and motor is increased
Solution Approach 1:
The patent transitions from vertical insulation (standing portion extending upward in the axial direction) to radial insulation (protrusion extending in the radial direction). This dimensional change allows insulation to be achieved without increasing the axial dimension of the busbar, thereby resolving the contradiction between insulation reliability and axial length.
Solution Approach 2:
Instead of extending the coil connector upward to achieve insulation, the patent inverts the approach by extending a protrusion in the radial direction from the busbar body. This inverted configuration provides the necessary insulation while maintaining a compact axial dimension.
2Reliability
If the coil connector extends upward to ensure insulation, then insulation is achieved, but the size of the motor is increased
Solution Approach 1:
The patent achieves insulation by extending a protrusion in the radial direction rather than the axial direction. This dimensional change prevents the motor from increasing in overall size, as the insulation structure now occupies radial space instead of axial space, thereby maintaining a compact motor volume.
Solution Approach 2:
The patent inverts the conventional insulation approach by using a radial protrusion instead of an axial standing portion. This inversion allows insulation to be achieved without compromising the compactness of the motor, thus preventing an increase in motor size.
3Length of moving object
If the busbar structure is simplified without standing portions, then the axial dimension is reduced, but insulation between busbars may be compromised
Solution Approach 1:
The patent maintains insulation reliability while simplifying the busbar structure by transitioning the insulation function from the axial dimension to the radial dimension. The protrusion extending radially provides adequate insulation between adjacent busbars without requiring axial extension, thus achieving both compactness and reliability.
Solution Approach 2:
The patent inverts the insulation approach by using a radial protrusion instead of an axial standing portion. This allows the busbar structure to be simplified (reduced axial dimension) while maintaining insulation reliability through the radial extension that provides sufficient clearance between busbars.
Data Source
AI summary
A motor includes a shaft disposed along a central axis extending in an up-down direction, a rotor assembly mounted on the shaft, a stator radially facing the rotor assembly with a clearance therebetween, and a plurality of busbars electrically connected to the stator. The busbar includes a first busbar and a second busbar. The first busbar has an upper disposed portion that is disposed above the second busbar. The second busbar has a busbar cavity that is recessed downward at a position that overlaps with the upper disposed portion in an axial direction.