Motor Terminal Block Merging Bus Bars for Hybrid Vehicle Power
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing motor designs for eco-friendly hybrid vehicles have a complex structure due to the use of multiple bus bars for connecting terminals and connectors, leading to increased component count, manufacturing costs, and energy losses, which result in frequent malfunctions and difficulty in meeting insulation standards.
Innovation Solution
A motor design that simplifies the connection structure by directly connecting terminals and connectors using a terminal block and power terminals, eliminating the need for bus bars, and incorporating a terminal module with a coupling member to ensure secure and efficient power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple bus bars are used to connect terminals and connectors, then electrical connection is achieved, but the number of components increases and structure becomes complicated
Solution Approach 1:
The patent combines multiple bus bars into a single integrated terminal block structure. The terminal block provides multiple connection points for terminals and connectors, eliminating the need for separate bus bars while maintaining electrical connectivity. This merging reduces component count and simplifies the overall structure.
Solution Approach 2:
The terminal block serves multiple functions: it acts as a structural support, provides electrical connection points for multiple terminals, and facilitates connector attachment. This multi-functional design replaces what previously required multiple specialized components (multiple bus bars), thereby reducing complexity while maintaining connection reliability.
2Reliability
If multiple bus bars are used for power reception, then electrical connection is established, but manufacturing cost increases
Solution Approach 1:
By merging multiple bus bars into a single terminal block component, the patent reduces the total number of parts that need to be manufactured, procured, and assembled. This consolidation directly reduces manufacturing costs while maintaining the necessary electrical connection functionality through the integrated design of the terminal block.
3Power
If multiple bus bars are used in the connection structure, then power transmission is achieved, but copper loss increases and heat is generated
Solution Approach 1:
The terminal block consolidates multiple copper connection elements into a single integrated structure, reducing the total length and number of copper joints. Fewer connection points mean fewer opportunities for electrical resistance and contact resistance, thereby reducing copper losses and heat generation while maintaining effective power transmission.
4Reliability
If multiple bus bars and components are used, then connection is established, but insulation distance requirements become difficult to meet
Solution Approach 1:
By integrating multiple connection functions into a single terminal block structure, the patent reduces the spatial distribution of conductive elements. This consolidation makes it easier to maintain adequate insulation distances between live parts and ground, as well as between different phases, compared to a dispersed arrangement of multiple bus bars.
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
This design reduces the number of components, lowers manufacturing costs, minimizes energy losses, and maintains insulation specifications, thereby enhancing the motor's reliability and efficiency.
Implementation Method 1
the power terminals are configured to penetrate through the terminal block, and at least one terminal located adjacent to the terminal block... such that the driving power is applied to the hairpin coils via the power terminal
Implementation Method 2
the at least one terminal may be configured to be brought into contact with the power terminal according to a movement of the connector when hairpin coils are inserted in the connector, such that the driving power is applied to the hairpin coils via the power terminal
Implementation Method 3
The at least one terminal may be configured to be fixed when a coupling member previously coupled to the power terminal is inserted in the at least one terminal according to the movement of the connector
Data Source
AI summary
The present disclosure provides a motor configured to receive driving power from a connector including power terminals. The motor comprises a housing, a terminal block disposed inside the housing, and at least one terminal located adjacent to the terminal block. The power terminals are configured to penetrate through the terminal block, and the at least one terminal is configured to be brought into contact with the power terminal according to a movement of the connector when hairpin coils are inserted in the connector, such that the driving power is applied to the hairpin coils via the power terminal.