Motor Stator Bus Bar Layout Without Terminals
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Solution Overview
Problem
The weight and production costs of automobile driving motors are increased due to the volume occupied by terminals, and the motor structure becomes complex, with insufficient insulation gaps, making manufacturing processes complicated and safety compromised.
Innovation Solution
A stator design with a central hole arranged in a circumferential direction, featuring multiple assemblies with a stator core, bobbin, and bus bars, where bus bars are strategically positioned and bent to form junction regions, eliminating the need for terminals and enhancing insulation safety by creating sufficient gaps between welding regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals are used to electrically connect assemblies to the power supply unit, then electrical connection is achieved, but weight and production costs increase due to the volume occupied by terminals
Solution Approach 1:
The patent extracts and eliminates the terminals from the motor structure. Instead of using separate terminal components to make electrical connections, the invention integrates the electrical connection function directly into the coil assembly by extending the lead-in and lead-out lines from the coil terminals through the bobbin to the stator core surface, where they can be directly connected to the power supply unit without requiring additional terminal components.
2Reliability
If terminals are used to electrically connect assemblies to the power supply unit, then electrical connection is achieved, but production costs increase due to the volume occupied by terminals
Solution Approach 1:
The patent extracts and eliminates the terminals from the motor structure. Instead of using separate terminal components to make electrical connections, the invention integrates the electrical connection function directly into the coil assembly by extending the lead-in and lead-out lines from the coil terminals through the bobbin to the stator core surface, where they can be directly connected to the power supply unit without requiring additional terminal components.
3Reliability
If terminals are used for electrical connection, then power supply connection is achieved, but the structure of the driving motor becomes complicated
Solution Approach 1:
The patent merges the electrical connection function with the existing coil and bobbin structure. The lead-in and lead-out lines are integrated into the bobbin structure, extending from the coil terminals through the bobbin to the stator core surface. This integration eliminates the need for separate terminal components and simplifies the overall motor structure by combining multiple functions into the existing assembly components.
4Reliability
If multiple welding regions are created in the motor, then electrical connections are established, but manufacturing processes become complicated
Solution Approach 1:
The patent extracts the welding operations from multiple distributed locations and consolidates them. By extending the lead lines to the stator core surface, all electrical connections can be made at a single location (the stator core surface), eliminating the need for multiple welding operations at different positions within the motor assembly.
5Productivity
If welding regions are closely positioned in the motor, then space is utilized, but safety for insulation is deteriorated due to insufficient gap
Solution Approach 1:
The patent transitions the electrical connection points from a two-dimensional plane within the motor assembly to a three-dimensional arrangement where connections are made at the stator core surface. This dimensional change allows sufficient insulation gaps to be maintained while still achieving effective space utilization, as the lead lines extend through the bobbin structure to reach the stator core surface at optimally spaced locations.
Data Source
AI summary
A stator for a motor includes a hole formed at a center thereof by arranging a plurality of assemblies along a circumferential direction (C) of the stator. Each of the plurality of assemblies includes: a stator core; a bobbin; a coil; and a plurality of bus bars disposed on the bobbin. The plurality of bus bars include first to third bus bars. In the plurality of assemblies, both ends of the first bus bar in the circumferential direction (C) and both ends of the second bus bar in the circumferential direction (C) are spaced apart from each other in the circumferential direction (C) while being spaced apart from each other in a radial direction (R) or an axial direction (A) of the stator.