Motor Connector Embossing Layout for Heat-Stable Terminal Fusing
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Solution Overview
Problem
The existing motors face issues with bonding and fusing quality at the terminal connections, leading to deformation and contact failures due to increased temperature, particularly at the fused portions of the terminals.
Innovation Solution
The motor design includes a stator with a busbar having first and second terminals separated in a circuit manner, connected via first and second connectors with embossings positioned asymmetrically relative to the stator center, and power terminals with bent fusing portions to improve bonding and fusing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar terminal and power terminal are fused together, then electrical connection is achieved, but the fused portion deforms and contact failure occurs due to temperature increase
Solution Approach 1:
The patent introduces an embossing structure as an intermediary element between the busbar terminal and power terminal. This embossing protrudes from the busbar terminal and engages with a corresponding recess in the power terminal, creating a mechanical interlock that distributes contact pressure and reduces localized heating, thereby preventing deformation and contact failure while maintaining electrical connection
Solution Approach 2:
The embossing and recess structures are pre-formed on the busbar terminal and power terminal before assembly. This preliminary formation of mating features ensures proper alignment and contact distribution from the outset, preventing excessive temperature rise during operation by establishing optimal contact conditions in advance
2Manufacturing precision
If the first embossing and second embossing are positioned asymmetrically relative to the stator center, then bonding quality is improved, but the structure becomes more complex
Solution Approach 1:
The patent deliberately employs asymmetric positioning of the first embossing and second embossing relative to the stator center. The first embossing on the first connector and the second embossing on the second connector are located at different radial distances from the stator center, creating unequal lever arms that optimize the bonding mechanical advantage and improve overall bonding quality while maintaining a relatively simple connector structure
Data Source
AI summary
The present invention provides a motor including a stator, a housing disposed outside the stator, a busbar disposed on an upper side of the stator, and a connector connected to the busbar, wherein the stator includes a stator core, an insulator disposed on the stator core, and a coil disposed on the insulator, the busbar includes a first terminal and a second terminal which are connected to the coil of the stator and separated from each other in a circuit manner, the connector includes a first connector fused to the first terminal and a second connector fused to the second terminal, each of the first connector and the second connector includes a connector body seated in the housing and a power terminal inserted into the connector body and fused to the first terminal or the second terminal, the power terminal includes a first embossing in contact with the second terminal and a second embossing in contact with the first terminal, and the first embossing is disposed closer to a center of the stator than the second embossing.