Motor Connection Terminal Bent Portion Rotor Insertion
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Solution Overview
Problem
The existing motor design faces difficulties in inserting the rotor into the stator core due to the radial disposition of the metal terminal, which interferes with the rotor insertion process during manufacturing.
Innovation Solution
The motor design includes a stator with a ring-shaped stator core and radially inward teeth, a rotor with a shaft and rotatable main body, and a busbar assembly with a connection terminal that has a lower terminal portion, a bent portion, and an upper terminal portion, allowing for precise alignment and insertion of the rotor into the stator core during manufacturing by moving the rotor in a direction intersecting with the axial direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection terminal extends radially inward to connect to the circuit board, then the electrical connection is achieved, but the terminal interferes with rotor insertion
Solution Approach 1:
The bent portion of the connection terminal creates a radial extension that achieves electrical connection without blocking the axial insertion path. By using a three-dimensional configuration instead of a straight radial extension, the terminal maintains its electrical function while clearing the rotor insertion path.
Solution Approach 2:
The bent portion acts as an intermediary structure that connects the axial lower terminal portion to the radial upper terminal portion, enabling electrical connection while maintaining clearance from the rotor insertion path.
2Manufacturing precision
If strict circumferential positioning is required for the metal terminal, then the electrical connection precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The bent portion provides radial positioning of the upper terminal portion without requiring strict circumferential positioning of the entire terminal assembly. The axial lower terminal portion can be positioned more easily, and the bent portion naturally provides the required radial offset to the upper terminal portion.
Data Source
AI summary
A connection terminal includes a lower terminal portion, a bent portion, and an upper terminal portion. The bent portion extends radially inward from an upper end of the lower terminal portion. The upper terminal portion extends axially upward from a radially inner end of the bent portion. The upper terminal portion is located radially inside a radially inner end surface of a tooth. In a process of manufacturing a motor, a rotor main body is inserted into a radially inner side of a stator core, using a space defined radially inside the lower terminal portion.