Motor Busbar Notch for Wire Positioning
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Solution Overview
Problem
The existing process of connecting conducting wires to busbars in motors is complex and difficult to automate due to the challenge of accurately positioning the wires, leading to complications in the connection process.
Innovation Solution
A motor design featuring a busbar with a notch for the conducting wire, where the inner surface includes a bottom surface and opposed surfaces that guide and secure the wire, allowing for easy insertion and caulking to establish a stable connection, facilitating the connection of the conducting wire to the busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional welding connection method is used to connect the conducting wire to the busbar, then the electrical connection can be established, but the positioning of the conducting wire is difficult to control and the process is complex
Solution Approach 1:
The busbar connection structure is segmented into distinct functional regions: a clamping portion for gripping the conducting wire, a positioning portion with lateral and longitudinal positioning surfaces for precise wire placement, and a welding portion for electrical connection. This segmentation allows each region to perform its specific function independently, simplifying the overall connection process while ensuring reliable electrical connection.
Solution Approach 2:
The conducting wire is pre-positioned using the positioning surfaces before the welding operation. The lateral positioning surface aligns the wire in the width direction, and the longitudinal positioning surface aligns it in the length direction. This preliminary positioning action eliminates the need for complex real-time positioning during welding, making the process easier to automate.
2Manufacturing precision
If the conducting wire position is not precisely controlled, then the connection process becomes complicated, but precise positioning requires complex positioning mechanisms
Solution Approach 1:
The busbar structure itself provides the positioning function through its geometric features. The lateral positioning surface and longitudinal positioning surface are integral parts of the busbar, forming a self-contained positioning system. The conducting wire is guided by these surfaces during insertion, and the clamping portion automatically grips the wire at the correct position. This self-service approach eliminates the need for separate external positioning mechanisms.
Solution Approach 2:
Positioning is achieved in multiple dimensions simultaneously: the lateral positioning surface controls the wire position in the width direction (lateral dimension), while the longitudinal positioning surface controls the position in the length direction (longitudinal dimension). This multi-dimensional positioning approach provides precise wire placement without requiring complex multi-axis positioning mechanisms.
Data Source
AI summary
A motor includes a rotor including a shaft extending along a central axis, a stator including a coil and opposing the rotor in a radial direction with a gap, and a busbar positioned at one axial-directional side of the stator. The busbar includes a conducting wire-connecting portion connected to a conducting wire extending from the coil. A notch into which the conducting wire is inserted is provided in the conducting wire connecting portion. An inner circumferential surface of the notch includes a bottom surface opposing an opening side of the notch, a first opposed surface extending from the bottom surface towards the opening, and a second opposed surface extending from the bottom surface towards the opening and opposing the first opposed surface.