Segmented Bus Bar Assembly for Lower-Cost Motor Winding Connections
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Solution Overview
Problem
The existing bus bar structures in electrical motors are diverse, leading to increased production costs and reduced product competitiveness due to the need for multiple sets of dies and long bus bar lengths that complicate molding.
Innovation Solution
A bus assembly comprising axially spaced bus bars with identical circumferentially arranged segments, reducing radial space requirements and allowing for shared dies, simplified processing, and improved production efficiency by using copper bus bars with uniform segments that can be connected by welding or arranged at intervals for better adaptation to stator winding requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sets of dies are used to prepare bus bars of different structures, then the bus bars can be customized to meet different electrical motor requirements, but the product costs increase and product competitiveness decreases
Solution Approach 1:
The bus bar is divided into multiple bus segments with identical structures, where each segment can be independently formed using the same die. This segmentation allows the bus bar to be customized for different motor requirements while using a single standardized die design, thereby reducing tooling costs while maintaining adaptability.
Solution Approach 2:
A single die design is created that can produce multiple bus segments universally applicable to different bus bar configurations. This universal die can serve multiple purposes across different electrical motor applications, eliminating the need for multiple specialized dies and reducing overall manufacturing costs while maintaining structural customization capabilities.
2Length of stationary object
If the length of a single bus bar in circumferential direction is relatively large, then the bus bar can connect distant winding ends, but the molding of the dies becomes difficult and costly
Solution Approach 1:
The long bus bar is segmented into multiple smaller bus segments of manageable lengths. Each segment can be easily formed using standard die molding processes without requiring complex or oversized dies. The segments are then connected to form the complete long bus bar structure, achieving both the required length and ease of manufacturing.
3Reliability
If multiple bus bars with different structures are used, then the electrical connections can be optimized for specific applications, but the number of dies increases and production efficiency decreases
Solution Approach 1:
While the overall bus bar structure can be optimized for specific electrical connection requirements, the local bus segments are standardized with identical structures. This allows the bus bar to maintain application-specific optimization while using standardized segments that can be produced efficiently with a single die design, thereby preserving both reliability and productivity.
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 solution reduces production costs, improves product competitiveness, and simplifies the assembly process by using fewer dies and adapting to various terminal assembly configurations while maintaining structural integrity and efficient electrical connections.
Implementation Method 1
the plurality of bus segments of one bus bar can be connected by welding, and thus one bus bar is formed
Data Source
AI summary
A bus assembly, an electrical motor, an electric power steering system, and a vehicle are provided. The bus assembly has multiple bus bars axially spaced along an electrical motor. Each bus bar has multiple bus segments arranged along the circumferential direction of the electrical motor. The bus segments of one of the bus bars have the same structure.