Electric Pump Bus Bar Layout for Stable Coil Connections
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Solution Overview
Problem
Existing electric pumps face challenges in maintaining efficient electrical connections and preventing short circuits due to positional displacement of bus bars and increased size, which affects the pump's performance and manufacturing costs.
Innovation Solution
The electric pump design incorporates a bus bar unit with C-shaped ring portions and radially extending hook portions that engage and weld with extended portions of the divided coils, utilizing insulating paper to prevent short circuits and maintain precise positioning, thereby reducing the risk of electrical misalignment and size increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bus bar connections are used, then electrical connections can be established, but positional displacement occurs and short circuits may happen
Solution Approach 1:
The bus bar is pre-formed with hook portions at specific positions and orientations before assembly. These hook portions are preliminarily shaped to engage with corresponding slots in the coil bobbins, ensuring correct positioning is established before the actual connection is made, thereby preventing positional displacement during assembly and operation.
Solution Approach 2:
The hook portions act as intermediary elements between the bus bar and the coil bobbins. These hooks provide a mechanical interface that mediates the connection, ensuring both electrical conductivity and precise positioning. The intermediary hook structure prevents direct contact misalignment and reduces the risk of short circuits.
2Reliability
If bus bars are made larger for better connection, then electrical stability improves, but the pump's axial size increases
Solution Approach 1:
The bus bar is segmented into functional portions: a body portion for electrical conduction and hook portions for mechanical engagement. This segmentation allows the bus bar to achieve stable electrical connections through the strategically positioned hooks without requiring an overall increase in the bus bar's dimensions, thus maintaining compact pump axial size.
Solution Approach 2:
The connection stability is achieved by extending the bus bar functionality into the radial dimension through hook portions that extend radially outward and engage with coil bobbins. This dimensional approach allows stable connections without increasing the axial length, as the engagement occurs in the radial direction rather than the axial direction.
3Reliability
If multiple bus bars are used for divided coils, then electrical connections are established, but manufacturing complexity increases
Solution Approach 1:
The bus bar design incorporates multiple hook portions that can engage with multiple coil bobbins, making the bus bar structure universal for connecting to divided coils. This multi-functional design allows a single bus bar to establish multiple electrical connections without requiring separate connection components for each coil, thereby reducing overall device complexity while ensuring complete electrical connectivity.
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 configuration effectively suppresses short circuits and positional displacement, reducing the pump's axial size and manufacturing costs while ensuring reliable electrical connections and efficient fluid handling.
Implementation Method 1
a plurality of divided iron cores surrounding an outer surface of the housing; a plurality of divided coil bobbins respectively attached to the plurality of the divided iron cores; a plurality of divided coils respectively wound around the plurality of the divided coil bobbins
Implementation Method 2
a part of the extended portion is engaged and welded with the hook portion
Data Source
AI summary
An electric pump includes an impeller, a rotor connected to the impeller, a housing housing the rotor, a plurality of divided iron cores surrounding an outer surface of the housing, a plurality of divided coil bobbins respectively attached to the plurality of the divided iron cores, a plurality of divided coils respectively wound around the plurality of the divided coil bobbins, and a bus bar unit including a plurality of bus bars.