Motor Busbar Layout Using Insulator Overlap to Cut Axial Size
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Solution Overview
Problem
The existing motor designs face challenges in reducing the axial size while maintaining space for a busbar, leading to increased motor size in the axial direction.
Innovation Solution
The motor design incorporates a stator with a stator core, coil, and insulator, where the busbar body and terminals overlap the insulator radially, and are positioned between the outer guide of the insulator and the inner circumferential surface of the housing, minimizing axial length by utilizing the outer space of the insulator as the busbar arrangement space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the busbar is disposed above the stator with a separate arrangement space, then the busbar can be properly installed and connected, but the motor size in the axial direction increases
Solution Approach 1:
The busbar structure is merged with the insulator structure by integrating the busbar arrangement space into the insulator's outer space. The insulator serves dual functions: electrical insulation and structural support for the busbar, eliminating the need for a separate busbar mounting structure and reducing overall axial length.
Solution Approach 2:
The busbar is nested within the insulator structure. The insulator's outer circumferential space, which would otherwise be unused, is utilized to accommodate the busbar body and terminals. This nesting arrangement allows the busbar to be disposed within the existing insulator volume, reducing the need for additional axial space.
2Length of moving object
If the busbar arrangement space is reduced to decrease axial size, then the motor becomes more compact, but the busbar structure becomes more complex
Solution Approach 1:
The insulator is designed with multi-functionality, serving both as an electrical insulator and as a structural component that provides the busbar arrangement space. The outer circumferential surface of the insulator is configured to accommodate the busbar, making the insulator a universal component that performs multiple functions and simplifies the overall busbar structure.
3Length of moving object
If the busbar is positioned to overlap the insulator radially, then the axial size is reduced, but the insulation requirements become more stringent
Solution Approach 1:
The insulator is designed with varying thickness to provide appropriate insulation at different locations. The insulator thickness is increased in regions where the busbar overlaps radially, ensuring sufficient electrical insulation distance is maintained. This local quality adjustment allows the busbar to be positioned in the radial overlap configuration while maintaining reliable insulation performance.
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
This configuration effectively reduces the motor's axial size while maintaining sufficient space for the busbar, simplifying the busbar structure and lowering manufacturing costs.
Implementation Method 1
A motor includes a rotor and a stator. The rotor is coupled to a shaft. When the rotor rotates, the shaft is rotated in conjunction with the rotation of the rotor. The stator may include a coil.
Data Source
AI summary
The present invention may provide a motor including a housing, a stator disposed in the housing, a rotor disposed in the stator, a shaft coupled to the rotor, and a busbar disposed above the stator, wherein the stator includes a stator core, a coil, and an insulator disposed between the coil and the stator, the busbar includes a busbar body and a plurality of terminals disposed in the busbar body, and at least a part of the busbar body and at least a part of the terminals are disposed to overlap the insulator in a radial direction.