Motor Bus Bar Holder Layout for Accurate Sealed Connections
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Solution Overview
Problem
The position accuracy of the upper bus bar holder in brushless motors is affected by the motor cover dimensions and assembly tolerance, leading to deviations. Additionally, the electrical connection between the upper and lower bus bar terminals is outside the motor cover, compromising dustproof and waterproof performance.
Innovation Solution
The upper bus bar holder is mounted on the edge of the motor casing, ensuring precise positioning without assembly tolerance. The electrical connection between the upper and lower bus bar terminals is located inside the casing, eliminating the need for a through hole in the motor cover and enhancing dustproof and waterproof performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the upper bus bar holder is mounted on the motor cover, then the bus bar can be positioned, but the position accuracy is affected by dimension and assembly tolerance resulting in deviation
Solution Approach 1:
The upper bus bar holder is extracted from the motor cover mounting location and repositioned to be mounted directly on the motor casing. This separation allows the bus bar holder positioning to be independent of the motor cover dimensions and assembly tolerances, thereby improving position accuracy while eliminating the source of dimensional deviation.
2Ease of manufacture
If the electrical connection position is located outside the motor cover, then the upper and lower bus bar terminals can be connected, but a through hole should be formed in the motor cover which has impact on dustproof and waterproof performance
Solution Approach 1:
Instead of placing the electrical connection outside the motor cover as conventionally done, the invention inverts the arrangement by locating the electrical connection inside the motor cover. The upper bus bar terminal extends through the motor cover from the inside, allowing connection to the lower bus bar terminal while maintaining the seal integrity of the motor cover, thus improving dustproof and waterproof performance without compromising electrical connectivity.
Data Source
AI summary
A motor includes a rotor, a stator, a casing accommodating the rotor and the stator and including an opening in an axial end, an upper bus bar assembly including an upper bus bar holder mounted on an edge of the opening of the casing and an upper bus bar (including an upper bus bar terminal) held on the upper bus bar holder, and a lower bus bar assembly including a lower bus bar holder located on an axially lower side of the upper bus bar holder and a lower bus bar (including a lower bus bar terminal) held on the lower bus bar holder. The upper bus bar terminal and the lower bus bar terminal are electrically connected inside the casing.