Segmented Bus-Bar Unit with Crank Junction
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Solution Overview
Problem
Conventional bus-bar units face challenges in increasing the number of bus-bars without significantly increasing manufacturing costs, and there are concerns about junction damage due to load transmission during external connection.
Innovation Solution
The bus-bar unit is designed with separate first and second bus-bar pieces, where the first piece has a coil wire connection and a junction terminal joined to the second piece, which includes an external connection terminal and a second junction terminal, with a crank portion to absorb stress and prevent junction damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bus-bar is formed by press working with a complicated shape to connect external terminal and coil wire connection part, then the routing function is achieved, but the manufacturing cost increases and the number of pieces taken from plate material decreases
Solution Approach 1:
The bus-bar is divided into multiple separate pieces (first bus-bar piece with coil wire connection part, second bus-bar piece with external connection terminal, and intermediate bus-bar pieces) that are joined together. This segmentation allows each piece to have a simpler shape that can be efficiently formed by press working, while the overall routing function is achieved through the assembly of multiple simpler components rather than one complex piece.
2Productivity
If the number of bus-bars is increased by separately forming members with external terminal and coil wire connection part and jointing them, then the manufacturing efficiency improves, but the junction becomes vulnerable to damage from load transmission
Solution Approach 1:
Load-absorbing structures are incorporated at the junctions between bus-bar pieces to cushion and absorb the loads transmitted during operation. This beforehand cushioning protects the junctions from damage, allowing the bus-bar system to be divided into multiple pieces for improved productivity while maintaining the reliability of the connections.
3Strength
If the bus-bar is formed as a single piece with complicated routing, then the structural integrity is maintained, but the manufacturing cost increases
Solution Approach 1:
The bus-bar is segmented into multiple pieces that are joined together using reliable joining methods. This segmentation enables each piece to be manufactured more efficiently through press working, reducing the overall manufacturing cost while maintaining structural integrity through proper design of the joining structures between pieces.
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 design allows for an increased number of bus-bars while reducing manufacturing costs and enhancing the stability of the junctions, preventing damage from vibration and load transmission.
Implementation Method 1
a crank portion located between the first extension and the second extension and bent in a crank shape or substantially a crank shape in a plate thickness direction
Data Source
AI summary
A bus-bar unit includes bus-bars and a bus-bar holder supporting the bus-bars. The bus-bar includes a first and a second bus-bar piece, including a plate. The first bus-bar piece includes a coil wire connecting portion connected to a coil wire drawn from a stator, and a first junction terminal joined to the second bus-bar piece. The second bus-bar piece includes an external connection terminal connected to an external device, a second junction terminal joined to the first bus-bar piece, and a second piece main body connecting them. The second piece main body has a first extension extending from the external connection terminal along a direction perpendicular or substantially perpendicular to the axial direction, a second extension extending from the second junction terminal along a direction perpendicular or substantially perpendicular to the axial direction, and a crank portion located between them and bent in a crank shape in a plate thickness direction.