Radial Bus Bar Housing with Coil Grooves for Motor Assembly
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Solution Overview
Problem
Conventional bus bar structures for motor coils require removal of coil film and separate punching or caulking for connection, which lowers workability and productivity.
Innovation Solution
A bus bar with radially disposed MAG-MATEs and bus bar housing that allows connection taps to be inserted with coils without removing the coil film, featuring a connection tap seating portion, coil coupling portion, and coil introducing groove for easy and reliable electric current conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the film of the coil is removed to improve electrical contact, then the electrical conduction reliability is improved, but the workability and productivity are lowered
Solution Approach 1:
The patent applies preliminary action by pre-coating the connection tap surface with a conductive material (such as silver plating or copper plating) before assembly. This preliminary preparation ensures that when the coil is inserted, the conductive surface is already ready to make good electrical contact without requiring film removal, thus maintaining both reliability and productivity
Solution Approach 2:
The patent introduces an intermediary conductive layer on the connection tap surface that acts as a mediator between the coil and the bus bar. This intermediate conductive coating ensures reliable electrical contact while allowing the coil film to remain intact, eliminating the need for film removal operations
2Reliability
If separate punching or caulking is performed after connection to ensure secure mounting, then the connection reliability is improved, but the workability is lowered
Solution Approach 1:
The patent merges the connection tap mounting structure with the bus bar housing by integrating the connection tap into the housing body. The connection tap is formed as an integral part of the housing with built-in positioning features and securing structures, eliminating the need for separate punching or caulking operations while maintaining secure mounting
Solution Approach 2:
The bus bar housing is designed with multi-functionality, serving both as the structural housing and as the mounting structure for connection taps. The housing incorporates features for both coil insertion and connection tap securing, reducing the number of separate manufacturing steps required
3Device complexity
If a conventional bus bar structure is used, then the manufacturing process is simple, but the coil connection capability and ease of connection are poor
Solution Approach 1:
The patent introduces a radial dimension to the connection tap arrangement, with connection taps disposed radially around the bus bar insertion groove. This spatial arrangement in another dimension allows coils to be easily inserted from the radial direction while maintaining a simple overall manufacturing process
Solution Approach 2:
The connection tap structure is designed to be self-aligning and self-securing. The radial arrangement and integrated housing structure allow the connection tap to automatically position itself and secure the coil without requiring complex external tools or multiple manufacturing steps, thus maintaining simplicity while improving ease of connection
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
Enhances the ease of connecting coils to bus bars, improving productivity by eliminating the need for film removal and separate punching, ensuring efficient electric current conduction.
Implementation Method 1
A bus bar housing having a plurality of MAG-MATEs disposed radially with respect to at least one or more bus bar insertion grooves
Data Source
AI summary
Disclosed is a bus bar having a plurality of connection taps formed radially therefrom, the bus bar including: first, second and third faces extended sequentially from the end of each connection tap in such a manner as to have a U-like side shape; and a coil insertion portion having a groove formed in a length direction of each connection tap on the center portions of the first, second and third faces and having a thickness lower than the thicknesses of the first, second and third faces, the coil insertion portion having a coil inserted into the groove thereof.