Segmented Bus Bar Guide for Motor Coil Connection Alignment

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Solution Overview

Problem

Conventional bus bar configurations face challenges in accurately positioning and connecting coils due to variations in shape and position, leading to potential displacement and unreliable connections.

Innovation Solution

A bus bar guide is introduced, comprising annularly arranged bus bar guide pieces with grooves that hold and position bus bars, absorbing shape and positional variations, and facilitating easy installation of bus bars in a motor assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If an integrally formed insulator is used to hold bus bars, then the structure is simple and manufacturing is easy, but it is difficult to absorb variations in shape and position of bus bars and coil terminals, leading to positional displacement and unreliable connections

Engineering Contradiction:

Improveease of manufactureVSAvoidconnection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The insulator is divided into multiple separate insulator pieces instead of being integrally formed. Each insulator piece can be independently positioned and adjusted to accommodate variations in bus bar shapes and coil terminal positions, thereby absorbing dimensional variations and ensuring reliable connections while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If an integrally formed insulator is used to hold bus bars, then the structure is simple, but it is difficult to arrange components at predetermined positions due to variations in shape and position, leading to assembly difficulties

Engineering Contradiction:

Improvestructural complexityVSAvoidassembly ease

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

By segmenting the insulator into multiple pieces, each piece can be independently positioned and adjusted during assembly. This allows components to be arranged at predetermined positions even when there are variations in bus bar shapes and coil terminal positions, significantly improving assembly ease while keeping the overall structure relatively simple.

Inventive Principle:

Principle #1Segmentation

3Reliability

If separate bus bar guide pieces are used to absorb variations, then connection reliability is improved, but the device complexity increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulator is segmented into multiple pieces that can be independently positioned and adjusted. This segmentation allows each piece to accommodate variations in bus bar shapes and coil terminal positions, improving connection reliability. The modular nature of the segmented insulator actually simplifies the overall device complexity compared to a monolithic structure that would require precise manufacturing tolerances.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP4080735B1Bus bar guide, bus bar assembly using same, and motor

Publication Date: 2025.12.03 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

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AI summary

A bus bar guide is provided to fix bus bars that connect a plurality of coils disposed in a motor. The bus bar includes a conductor that has a plate shape and has a first surface and a second surface continuous with the first surface. The bus bar guide is configured by annularly arranging a plurality of bus bar guide pieces each including an insulator. Each of the plurality of bus bar guide pieces is provided with a groove that holds the first surface of the bus bar and positions the bus bar.