Neutral Busbar Bent Structure for Stable Armature Temperature Sensing
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Solution Overview
Problem
In rotating electric machines, the strain induced during the adjustment of connection terminals on the neutral busbar can cause the U-shaped bent part to spread, making it difficult to reliably retain the temperature sensor, leading to potential displacement and insufficient contact, which compromises the accuracy of temperature detection.
Innovation Solution
The configuration includes first and second extending portions that act as buffer members to absorb strain during connection terminal adjustment, ensuring the temperature sensor remains in contact with the bent part of the neutral busbar, and the use of a resin member with through-holes and pressing members to secure the sensor during resin molding prevents displacement and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection terminals are adjusted on the neutral busbar, then electrical connection reliability is improved, but the bent part spreads due to induced strain, making it difficult to retain the temperature sensor
Solution Approach 1:
The neutral busbar is divided into a first part and a second part, with the bent part formed between them. This segmentation allows the connection terminals to be adjusted on each part independently while the bent part remains a distinct structural element that can retain the temperature sensor, thus resolving the contradiction between connection reliability and sensor retention precision.
Solution Approach 2:
The bent part acts as an intermediary element between the first and second parts of the neutral busbar. It provides a dedicated structure for temperature sensor retention while allowing the connection terminals on the first and second parts to be adjusted for reliable electrical connection, thus mediating between the two competing requirements.
2Ease of manufacture
If the bent part is made flexible to allow terminal adjustment, then ease of assembly is improved, but deformation occurs causing temperature sensor displacement
Solution Approach 1:
By segmenting the neutral busbar into first and second parts with the bent part between them, the structure gains flexibility for assembly while the bent part maintains its shape to retain the temperature sensor accurately, resolving the contradiction between assembly ease and position accuracy.
3Reliability
If pressing members are used during resin molding to secure the temperature sensor, then sensor retention reliability is improved, but short circuit risk increases due to potential contact between busbar parts
Solution Approach 1:
The harmful factor (short circuit risk) is extracted and eliminated by using the resin member as an insulating barrier between the first and second parts of the neutral busbar. The pressing members can securely retain the temperature sensor on the bent part without causing short circuits, as the resin prevents electrical contact between the busbar parts.
Solution Approach 2:
The resin member acts as an intermediary that provides both mechanical support for the pressing members to secure the temperature sensor and electrical insulation to prevent short circuits between the first and second parts, thus resolving the contradiction between retention reliability and short circuit prevention.
Data Source
AI summary
A rotating electric machine includes a neutral busbar and a temperature sensor. The neutral busbar has a main body and a bent part that retains the temperature sensor therein. The main body has first and second parts each of which has one or more connection terminals formed therein. The bent part is formed between a circumferential end portion of the first part and a circumferential end portion of the second part. In the first part, there is formed, between the circumferential end portion of the first part and a closest connection terminal formed in the first part to the bent part, a first extending portion that extends axially or radially. Similarly, in the second part, there is formed, between the circumferential end portion of the second part and a closest connection terminal formed in the second part to the bent part, a second extending portion that extends axially or radially.