Motor Power Busbar Plug Assembly for Vibration-Resistant Connections
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Solution Overview
Problem
Conventional electric power supply devices for BLDC motors in electric vehicles are prone to damage due to loose connections caused by vibrations, which can lead to a broken welded joint and disrupt the power supply.
Innovation Solution
An integrated electrical connection unit with a busbar arrangement and an insulating plug is used, allowing for external connection to an electrical power supply without the need for welding, providing a secure and vibration-resistant connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welded connections are used to connect busbars to connection plates in the housing, then electrical conduction is achieved, but the connections become loose or break due to vibrations during motor operation
Solution Approach 1:
The connection unit is divided into separate modular components: busbars, insulating plug, and housing. This segmentation allows each component to be optimized independently - the busbars can be mechanically connected without welding, eliminating the vibration-induced connection failure while maintaining electrical conductivity.
Solution Approach 2:
The patent replaces the welded mechanical connection system with a mechanical insertion system. The busbars are inserted into the insulating plug and secured through mechanical means (such as clamps or friction fit) rather than thermal welding, thereby eliminating the harmful effects of vibration on welded joints while maintaining secure electrical connection.
2Reliability
If welded connections are used for power supply connections, then electrical conduction is established, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The busbars are pre-assembled with the insulating plug to form an integrated connection unit before installation into the housing. This preliminary assembly eliminates the need for on-site welding operations during final assembly, significantly reducing assembly time and complexity while ensuring reliable electrical connections are already established.
Solution Approach 2:
Multiple components (busbars, insulating plug, and mounting structures) are merged into a single integrated connection unit. This consolidation reduces the number of separate assembly steps, eliminates the need for welding operations, and allows the entire power supply connection system to be installed as one module, thereby improving productivity without compromising reliability.
3Reliability
If busbars are welded to connection plates inside the housing, then electrical connection is achieved, but the risk of mechanical damage to connections increases under vibration
Solution Approach 1:
An insulating plug is introduced as an intermediary component between the busbars and the housing environment. This plug provides both electrical insulation and mechanical support, allowing the busbars to be securely held in position without direct welding to the housing or connection plates, thereby protecting the electrical connections from vibration-induced damage.
Solution Approach 2:
The patent replaces the welded mechanical connection system with a mechanical insertion system. The busbars are inserted into the insulating plug and secured through mechanical means rather than thermal welding, thereby eliminating the harmful effects of vibration on welded joints while maintaining secure electrical connection.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electric power supply device (1) for an electric motor (30). The electrical power supply device (1) comprises a housing (2) which at least partially surrounds a housing interior (3). The housing has a housing opening (4) which can preferably be closed by means of a housing cover. In addition, the housing is pot-shaped and has a pot base (5) and a pot collar (6) projecting at an angle, preferably at right angles, from the pot base (5). An electrical connection unit (15) is arranged in the housing interior (3), which comprises a busbar arrangement (10) with at least three (11a-11d), preferably with four, electrical busbars (11a-11d) for the electrical power supply of the motor (3). The busbars are designed in such a way that they can be electrically and mechanically connected to a respective electrical connection element (32a-32c) of the electric motor (30) arranged on the pot base (5) for electrically energizing the same. The electrical connection unit (15) further comprises a plug (16) arranged at least partially in a feed-through opening (7) formed on the pot collar. The plug comprises a plug housing (17) in which respective end portions (12a-12d) of the bus bars (11a-11d) are arranged. Furthermore, plug (16) merges into a flange section (18) of the connection unit (15). By means of the flange section, the connection unit (15) can be fixed or is fixed on the pot bottom (5) of the housing (2).