Motor Terminal Leg Structure for Compact Radial Packaging
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Solution Overview
Problem
The existing motor designs increase the thickness of applications, such as steering apparatuses, due to the radial distance between the shaft and the terminal part, which complicates the fusing process and affects the overall thickness of the application.
Innovation Solution
The motor design includes a terminal part with a terminal body and second terminals connected to the busbar, where the terminal body is spaced apart from the housing with legs that contact the housing, and the second terminals are positioned between the rotor and the housing's inner surface in a radial direction, reducing the radial distance between the shaft and the terminal part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal of the terminal part is disposed outside the busbar in the radial direction to secure fusing space, then the fusing process is facilitated, but the thickness of the application (e.g., steering apparatus) increases
Solution Approach 1:
The patent repositions the terminal from a radial arrangement (outside the busbar) to an axial arrangement (within the busbar structure). The terminal is disposed inside the busbar body along the axial direction, with the terminal body extending axially and the terminal exposed at the end surface, transforming the spatial dimension from radial to axial to reduce overall thickness while maintaining fusing capability
Solution Approach 2:
The terminal is nested within the busbar structure. The terminal body is disposed inside the busbar body, and the terminal is exposed at the end surface of the busbar, creating a nested configuration where the terminal is contained within the busbar's volumetric space rather than extending radially outward, thereby reducing the application's thickness
2Length of stationary object
If the terminal part is positioned closer to the shaft to reduce application thickness, then the overall thickness is reduced, but the fusing space between the terminal and busbar becomes limited
Solution Approach 1:
The patent resolves the space limitation by changing the fusing dimension from radial to axial. The terminal body extends axially within the busbar body, and the terminal is exposed at the axial end surface, allowing the fusion member to be disposed axially between the terminal and busbar end surfaces, thus providing adequate fusing space without increasing radial thickness
Solution Approach 2:
The patent creates a localized fusing region at the axial end surface of the busbar. The terminal body is disposed within the busbar body with the terminal exposed at the end surface, concentrating the electrical connection and fusing function at this specific axial location, which optimizes the fusing space utilization without affecting the overall radial dimensions
Data Source
AI summary
The present invention may provide a motor including a housing, a stator busbar, and a terminal part connected to the busbar, wherein the busbar includes a first terminal, the terminal part includes a terminal body and a second terminal connected to the first terminal, the terminal body includes a body disposed to be spaced apart from an upper end of the housing and legs which extend from the body and are in contact with the housing, a width of each of the legs in a circumferential direction is smaller than a width of the body in the circumferential direction, the first end portion is disposed between the rotor and an inner circumferential surface of the housing in a radial direction, and the second end portion is disposed between a lower surface of the body and the upper end of the housing in an axial direction.