Motor Busbar Holder Assembly for Precise Terminal Positioning
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Solution Overview
Problem
Existing brushless motors face issues with insufficient positioning accuracy of terminals due to cumulative tolerances between the stator and busbar assembly, leading to misalignment in the axial and circumferential directions.
Innovation Solution
The motor design includes a support plate with axially penetrating through-holes for the busbar assembly, combined with a stepped housing component and interference fitting, to improve positional accuracy by minimizing cumulative tolerances and facilitating easier busbar connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single integrated busbar assembly is used with the stator, then the structure is simple and easy to manufacture, but the positioning accuracy of terminals in axial and circumferential directions is insufficient due to cumulative tolerances
Solution Approach 1:
The busbar assembly is divided into an upper busbar holder and a lower busbar holder that are positioned on opposite sides of the stator. This segmentation allows each holder to be independently positioned and fixed, eliminating the cumulative tolerance issues that occur in single-integrated assemblies. The upper holder is fixed to the housing while the lower holder is fixed to the stator, creating separate reference surfaces for each component.
Solution Approach 2:
The housing serves as an intermediary reference surface between the upper busbar holder and the stator. By fixing the upper holder to the housing and the lower holder to the stator, the housing acts as a stable mediator that establishes precise positional relationships. This intermediary approach allows the terminal positions to be accurately controlled through the housing's reference surface rather than relying on direct fitting between stator and busbar assembly.
2Manufacturing precision
If the upper busbar holder is tightly fitted to the support plate, then the positioning accuracy is improved, but the rib component may be damaged during assembly
Solution Approach 1:
The rib component is designed with dynamic characteristics that allow it to expand radially outward during the assembly process. When the upper busbar holder is pressed onto the support plate, the rib component can flex and expand to accommodate the interference fit, adjusting the concentricity of the assembly. This dynamic behavior prevents the rib component from being damaged while still achieving the desired tight fit and positioning accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the positioning accuracy of terminals in both the axial and circumferential directions, ensuring reliable electrical connections and efficient assembly without occupying additional motor space.
Implementation Method 1
when the upper busbar holder is pressed into the support plate, the rib component may expand radially outwards to adjust the concentricity of the upper busbar holder and the support plate
Data Source
AI summary
Disclosed is a motor, which includes: a housing; a support plate fixed on the housing; an upper busbar holder holding the upper busbar and defined on the support plate; a lower busbar holder holding the lower busbar; one end of the upper busbar is connected to the lower busbar, and the other end of the upper busbar is connected to an external power supply; one end of the lower busbar is connected to the coil lead wire, and the other end of the lower busbar is connected to the upper busbar, the upper busbar holder has a first through-hole penetrating in the axial direction, the support plate has a second through-hole penetrating in the axial direction; the other end of the lower busbar passes through the first through-hole and the second through-hole, and is connected to one end of the upper busbar.