Vehicle Motor Bus Bar Coupling to Prevent Welded Joint Cracks
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Solution Overview
Problem
The continuous vibration during high-speed driving of motors in eco-friendly vehicles causes cracks or fractures in the welded connection between the bus bar and conductive connection terminal, leading to disconnection and hindered power supply to the stator coil.
Innovation Solution
A power supply system for a vehicle motor that includes an elastic member made of rubber, covering the bus bar and conductive connection terminal, with a press-fitting groove and support ribs to reduce vibration and guide the components to move in the same direction, preventing cracks and fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar and conductive connection terminal are rigidly connected by welding, then electrical connection is established, but vibration causes cracks and disconnection in the welded portion
Solution Approach 1:
The patent applies this principle by using an elastic member (flexible element) that envelops the conductive connection terminal and bus bar. This flexible structure allows relative movement between the rigid welded portions while maintaining electrical connection, preventing vibration-induced cracks from propagating through the entire connection assembly.
Solution Approach 2:
The patent implements dynamics by introducing an elastic member that can dynamically adapt to vibration-induced movements. The elastic member deforms elastically under vibrational stress, allowing the connection to accommodate dynamic loads rather than resisting them rigidly, thereby preventing fatigue failure.
2Device complexity
If the terminal block is mounted on the motor housing, then power supply structure is simplified, but differential vibration between housing and stator causes welded portion weakening
Solution Approach 1:
The elastic member serves as an intermediary element between the rigid welded connection and the external environment. It mediates the differential vibration forces by absorbing and isolating them, allowing the simplified power supply structure to maintain reliability despite the vibration mismatch between motor housing and stator.
3Productivity
If vibration is continuously applied to the welded portion, then power supply operation continues, but cracks and fractures occur leading to disconnection
Solution Approach 1:
The elastic member provides beforehand cushioning by being pre-installed in the connection assembly. It is designed to absorb and dampen vibration forces before they can cause cumulative damage to the welded portion, preventing cracks and fractures from developing during continuous operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The elastic member effectively reduces vibration, ensuring durable electrical connections by preventing disconnection and fractures in the welded portion, maintaining power supply to the stator coil.
Implementation Method 1
Because vibration due to high-speed driving of the motor is continuously applied to the bus bar 32 and the conductive connection terminal 42 that are connected to each other by the welded portion 50, cracks or fractures occur in the welded portion 50
Implementation Method 2
an elastic member that reduces vibration is mounted on a bus bar of a terminal plate and a conductive connection terminal of a stator coil that are electrically connected to each other
Data Source
AI summary
A power supply of a motor for a vehicle includes: a terminal block mounted to a motor housing to prevent disconnection of a terminal connection portion configured to supply power to a stator coil of the motor; a terminal plate electrically connected to the terminal block; a bus bar provided on the terminal plate; a stator coil having a conductive connection terminal electrically connected to the bus bar; and an elastic member mounted to the bus bar and the conductive connection terminal to reduce vibration applied to the bus bar and the conductive connection terminal.