Motor Stator Busbar Layout for Accurate Power Terminal Positioning

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Solution Overview

Problem

The manufacturing process of motor terminals is complicated, leading to high scrap generation and increased mold and process numbers, and positional deviations of power terminals due to axial tolerances, causing defects in the motor.

Innovation Solution

A motor design featuring a busbar with protrusions and grooves arranged in a circular orbit, allowing for precise alignment and connection of terminals, reducing scrap and positional deviations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If terminals are manufactured with complex shapes and sizes to accommodate various power terminal positions, then adaptability to different positions is improved, but manufacturing complexity and scrap generation increase

Engineering Contradiction:

Improveadaptability to various power terminal positionsVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The busbar body is designed with multiple first protrusions that can accommodate power terminals at various positions along the same circular orbit. This universal design allows a single busbar structure to serve multiple positioning requirements, eliminating the need for different terminal shapes and sizes for different positions, thereby reducing manufacturing complexity while maintaining adaptability

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If power terminals are connected to external power source with long lengths, then electrical connection capability is improved, but shape complexity of development figure increases

Engineering Contradiction:

Improveelectrical connection capabilityVSAvoidshape complexity of development figure

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The busbar body features a circular orbit arrangement of first protrusions, providing a curved geometric path that naturally accommodates long power terminals. This circular configuration simplifies the development figure shape compared to irregular layouts, while still allowing sufficient length for reliable electrical connections to the external power source

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of manufacture

If axial tolerances are present in assembly process, then manufacturing flexibility is improved, but positional accuracy of power terminals deteriorates

Engineering Contradiction:

Improveassembly flexibilityVSAvoidpositional accuracy of power terminals

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The circular orbit design with multiple equidistant first protrusions provides a pre-planned tolerance distribution system. Axial tolerances in the assembly process are cushioned by the symmetric arrangement, which ensures that positional deviations remain within acceptable limits and do not cause cumulative errors, thereby maintaining manufacturing precision despite assembly flexibility

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12506379B2Motor and stator busbar

Publication Date: 2025.12.23 LG INNOTEK CO LTD

AI summary

The present invention may provide a motor including a shaft, a rotor coupled to the shaft, a stator disposed outside the rotor, a busbar disposed above the stator, and a power terminal unit coupled to the busbar connected to the coils, wherein the power terminal unit includes a first groove, the busbar includes a busbar body and a plurality of terminals disposed on the busbar body, the busbar body includes a plurality of first protrusions protruding from an upper surface of the busbar body and disposed in the first groove, and the plurality of first protrusions are disposed on the same circular orbit based on a center of the busbar.