Motor Busbar Notch Structure for Stable Temperature Sensor Mounting
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Solution Overview
Problem
Existing motors face challenges in stably securing temperature sensors on busbars, particularly due to interference fit methods that complicate installation and may lead to instability.
Innovation Solution
The temperature sensor is installed on the busbar by passing through multiple notches or passing portions in the busbar, which facilitates stable attachment and improves ease of installation, while maintaining electrical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If interference fit method is used to install temperature sensor on neutral busbar, then temperature sensor can be held on busbar, but installation becomes complicated and stability is compromised
Solution Approach 1:
The busbar is divided into multiple segments with notches at different positions along its length. The temperature sensor is passed through these segmented notches, creating multiple attachment points that stabilize the sensor without requiring complex interference fit procedures. This segmentation approach simplifies installation while ensuring reliable sensor positioning.
2Ease of operation
If notch is provided in busbar to facilitate temperature sensor installation, then ease of installation improves, but electrical resistance of busbar increases
Solution Approach 1:
The busbar structure is modified with notches only at specific locations where temperature sensor attachment is needed, while the main body of the busbar maintains its full cross-sectional area and optimal electrical conductivity. This localized modification approach allows easy sensor installation without significantly impacting the overall electrical performance of the busbar.
Solution Approach 2:
Instead of reducing the busbar's cross-sectional area (two-dimensional approach), the solution adds notches that extend in the third dimension (depth-wise) at specific locations. This allows the temperature sensor to pass through and attach to the busbar without removing significant material from the busbar's main conductive path, thereby maintaining low electrical resistance.
3Reliability
If temperature sensor is passed through multiple passing portions, then temperature sensor is stably held on busbar, but busbar structure becomes more complex
Solution Approach 1:
The notches are pre-formed in the busbar during manufacturing, creating ready-made passage points for the temperature sensor. This preliminary preparation eliminates the need for complex assembly operations or additional components, as the busbar itself provides the attachment structure. The multi-notch design stabilizes the sensor through multiple contact points while keeping the overall structure simple and integrated.
Data Source
AI summary
A motor includes: a stator core having a tubular shape; a plurality of coils installed in the stator core; a busbar configured to be electrically connected to at least one of the coils; and a temperature sensor installed on the busbar. The busbar includes a plurality of passing portions. At least part of the temperature sensor passes through each of the passing portions and is installed on the busbar.