Motor Busbar Terminal Layout for Axial Overlap Coil Connection

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Solution Overview

Problem

In existing motor configurations, the coil cannot be connected to the busbar terminal due to overlapping with the external connection terminal in the axial direction.

Innovation Solution

The motor design includes a busbar terminal with multiple layers in the axial direction, featuring both an external connection terminal and a coil connection terminal. The coil terminal part is formed to extend in the circumferential direction, allowing connection to the coil connection terminal without interference from the external connection terminal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the coil is linearly extended in the axial direction to connect to the busbar terminal, then the connection is simple, but the coil cannot be connected when overlapping with the external connection terminal

Engineering Contradiction:

Improvecoil connection processVSAvoidconnection position flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The coil terminal part is formed to extend in the circumferential direction instead of only in the axial direction, changing the dimension of extension. This allows the coil terminal part to reach the coil connection terminal even when the coil overlaps with the external connection terminal in the axial direction, thereby resolving the connection issue while maintaining manufacturing simplicity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If the busbar terminal has multiple layers overlapping in the axial direction to accommodate both external connection terminal and coil connection terminal, then both terminals can be provided, but the space arrangement becomes more complex

Engineering Contradiction:

Improveterminal arrangement flexibilityVSAvoidbusbar terminal structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The busbar terminal is divided into multiple layers in the axial direction, with different terminals arranged in different layers. The external connection terminal and coil connection terminal are positioned in different axial positions, allowing both terminals to be accommodated while maintaining clear spatial separation and reducing structural complexity

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If the coil terminal part is formed to extend in the circumferential direction, then connection is possible regardless of external connection terminal position, but the forming process becomes more complex

Engineering Contradiction:

Improveconnection position flexibilityVSAvoidcoil terminal forming process

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The coil terminal part is pre-formed during the coil winding process to extend in the circumferential direction. This preliminary forming action ensures that the coil terminal part is already in the correct position and orientation before assembly, facilitating connection to the coil connection terminal without requiring additional complex forming operations

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250047165A1Motor

Publication Date: 2025.02.06 MITSUBA CORP

AI summary

A motor includes a busbar terminal including a plurality of layers overlapping in an axial direction. In the busbar terminal, an external connection terminal and a coil connection terminal are formed. A coil terminal part that is pulled out from a winding part overlapping the external connection terminal in the axial direction is connected to the coil connection terminal while being subjected to forming to be pulled out in a circumferential direction.