Motor Busbar Positioning via Housing Reference Surface
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Solution Overview
Problem
Existing motors face challenges in accurately positioning the busbar unit relative to the stator due to the arrangement of components, leading to reduced accuracy and potential assembly difficulties.
Innovation Solution
The motor design includes a rotor, stator, bearing, housing, bearing holder, and busbar unit, where the busbar unit is positioned on the upper side of the bearing holder and in contact with the housing inner circumferential surface, allowing for precise alignment and attachment with the stator, enhancing positional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bearing holder is arranged between the busbar unit and the stator, then the bearing holder can support the bearing, but the busbar unit cannot be attached to the stator core to position it with high accuracy
Solution Approach 1:
The patent introduces the housing inner circumferential surface as an intermediary positioning reference. Both the busbar unit and stator are positioned relative to this common reference surface, enabling high-accuracy positioning without requiring direct attachment between the busbar unit and stator core. The housing acts as a mediator that facilitates precise alignment while maintaining the bearing holder's structural support function.
2Manufacturing precision
If the busbar unit is positioned on the upper side of the bearing holder, then the positioning accuracy is improved, but the assembly process becomes more complex
Solution Approach 1:
The housing inner circumferential surface serves multiple functions: it provides structural containment for the stator, acts as a positioning reference for the busbar unit, and serves as a mounting surface for the bearing holder. By making this surface multi-functional, the patent achieves high positioning accuracy without adding separate positioning mechanisms, thus avoiding increased assembly complexity.
3Manufacturing precision
If the busbar unit is positioned with high accuracy relative to the stator, then the positioning precision is improved, but the risk of coil wire damage during assembly increases
Solution Approach 1:
The patent establishes the positioning reference on the housing inner circumferential surface before assembling the busbar unit and stator. By pre-defining the positioning geometry on the housing, the alignment between busbar unit and stator is predetermined, reducing the need for forceful adjustments during assembly that could damage coil wires. The positioning is achieved through the preliminary configuration of the housing reference surface.
Data Source
AI summary
A motor may include a rotor including a shaft; a stator arranged radially outside of the rotor; a bearing arranged on an upper side of the stator; a tubular housing; a bearing holder arranged on the upper side of the stator; and a busbar unit arranged on an upper side of the bearing holder. The rotor may include a rotor magnet fixed to the shaft. The stator may include an annular core back; teeth arranged to extend radially inward from the core back; and coils wound around the teeth. The housing may include a housing inner circumferential surface arranged to hold the stator. The bearing holder may be arranged to be in contact with the housing inner circumferential surface. The busbar unit may be arranged to be in contact with the housing inner circumferential surface.