Segmented Busbar Terminal Structure to Reduce Scrap and Plating Cost
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Solution Overview
Problem
Conventional busbar terminals generate significant scraps during production and require complex plating processes, leading to increased production costs.
Innovation Solution
A busbar terminal structure is designed with a coupling of two members, featuring a busbar body and power terminal parts that are separately formed and plated, minimizing scraps and reducing plating costs through a barrel plating method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional busbar terminal is formed by cutting one plate member and bending it multiple times, then the structural integrity is improved, but the amount of scraps generated increases significantly
Solution Approach 1:
The busbar terminal is divided into two separate members: a body part formed by cutting and bending a first plate member, and a power terminal part formed from a second plate member. These two members are subsequently coupled together through a fusing process, eliminating the need for excessive material removal while maintaining structural integrity.
Solution Approach 2:
The invention changes the manufacturing approach from forming a single complex piece through multiple bending operations to a two-stage process: first forming simpler components with minimal bending, then coupling them through fusing. This parameter change in the manufacturing process significantly reduces scrap generation.
2Reliability
If plating process is performed on the entire conventional busbar terminal, then the corrosion resistance is improved, but the production cost increases
Solution Approach 1:
Instead of plating the entire busbar terminal, the invention applies plating selectively only to the power terminal part which requires corrosion resistance for external power connection. The body part, which is primarily structural, does not require plating, thus reducing material costs and production expenses.
3Strength
If a complex bending structure is used in the conventional busbar terminal, then the mechanical strength is improved, but the plating process becomes more difficult and costly
Solution Approach 1:
The complex structure is segmented into two separate members with simpler geometries. The body part contains the necessary bending for structural strength, while the power terminal part is a separate component that requires plating. This segmentation eliminates the need for complex multi-bend structures that would require costly rack plating methods.
4Shape
If multiple bending processes are performed to form the conventional busbar terminal, then the structural configuration is improved, but the manufacturing time and cost increase
Solution Approach 1:
The manufacturing process is segmented into parallel streams: the body part is formed through cutting and minimal bending operations, while the power terminal part is formed separately. These operations can be performed simultaneously or in optimized sequences, reducing total manufacturing time compared to forming a single complex structure through multiple sequential bending operations.
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 minimizes scrap generation and lowers production costs by optimizing the manufacturing process, allowing for efficient plating of power terminal parts while maintaining robust connections.
Implementation Method 1
each of the busbar terminals includes a body part and a power terminal part coupled to the body part, the body part includes a body, a plurality of terminals disposed on the body, and a protrusion protruding from an upper surface of the body in an axial direction
Data Source
AI summary
An embodiment provides a motor comprising: a stator; a rotor arranged to correspond to the stator; a shaft coupled to the rotor; and a busbar disposed above the stator, wherein: the busbar comprises a busbar body and a plurality of busbar terminals disposed in the busbar body; each of the busbar terminals comprises a body part and a power terminal part coupled to the body part; the body part comprises a body, a plurality of terminal portions disposed in the body, and a protrusion protruding in the shaft direction from the upper surface of the body; and one surface of the lower portion of the power terminal part comes into contact with the inner surface of the protrusion. Accordingly, the motor uses the busbar terminal having the structure in which the power terminal part is coupled to the body part, and thus scraps produced during the formation of the busbar terminal can be minimized.