Motor Busbar Layout for Variable Torque Without Added Length
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Solution Overview
Problem
Existing electric motor designs face challenges in achieving variable torque output without significant design changes, especially in types like in-wheel motors, leading to increased costs and time due to space constraints and the need to accommodate varying torque requirements.
Innovation Solution
A stator assembly with a winding arrangement featuring hairpin-configured windings and a busbar that connects these windings without adding height, along with a rotor assembly allowing for magnet combinations to vary torque output, and a busbar configuration that does not increase motor length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the busbar is installed onto the winding arrangement covering the top-most end of windings, then the electrical connection is simplified, but the motor length increases
Solution Approach 1:
The busbar is repositioned from a vertical installation (covering the top-most end of windings in the axial direction) to a horizontal installation along the inner surface of the stator core. This dimensional change allows the busbar to maintain electrical connectivity while eliminating the height contribution that previously increased motor length.
2Adaptability or versatility
If the motor design is significantly changed to accommodate varying torque requirements, then the torque output can be adjusted, but the development time and cost increase
Solution Approach 1:
The motor design incorporates a universal structure with a standardized stator core, winding arrangement, and busbar configuration that can accommodate multiple torque requirements. By using the same motor design across different drive modes (FWD, RWD, AWD) and varying torque outputs, the system achieves multi-functionality without requiring separate development cycles for each application.
3Adaptability or versatility
If components are added to the motor to achieve variable torque output, then the torque requirements can be met, but the motor length increases
Solution Approach 1:
The busbar is merged with the stator core structure by installing it along the inner surface, integrating the electrical connection component into the existing motor architecture. This merging eliminates the need for additional space in the axial direction, as the busbar utilizes the existing structural envelope of the stator core rather than adding external protrusions.
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
Enables variable torque output in electric motors without altering the motor's length, simplifying design changes and reducing costs by maintaining a consistent motor design across different drive modes.
Implementation Method 1
a busbar comprising at least one jumper that electrically connects one or more of the windings to one another
Implementation Method 2
a motor is a well-known electrical machine that converts electrical energy into mechanical energy using magnetic field linkage
Data Source
AI summary
A motor includes: a stator assembly; and a rotor assembly configured to be rotatable relative to the stator assembly. The stator assembly includes: a stator core having stator slots; a winding arrangement made up of windings, the winding arrangement including a non-exposed portion where a portion of the each of the windings is inserted within respective ones of the stator slots and an exposed portion where a top-most end of each of the windings extends outward from the stator core; and a busbar including at least one jumper that electrically connects one or more of the windings to one another, the busbar being installed onto the winding arrangement without covering the top-most end of each of the windings.