Stacked High-Voltage Terminal for Compact Stator Integration
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Solution Overview
Problem
Existing high-voltage terminals for electrical machines are not optimized for compact integration within limited installation spaces, leading to inefficiencies in stator windings and electrical machines.
Innovation Solution
A high-voltage terminal design featuring three bus bars and a star bar, stacked and electrically insulated with a plastics element, allowing for 4 parallel paths per phase in a compact configuration, reducing component count and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional high-voltage terminal designs are used, then electrical connection functionality is provided, but the installation space required is excessive and compact integration is not achieved
Solution Approach 1:
Multiple current output elements (at least n≥4 parallel elements) are merged into a single bus bar structure, and the star bar with at least 3n current input elements integrates multiple phase connections. This merging of multiple electrical connection paths into unified bar structures reduces the overall volume and enables compact integration while maintaining full electrical functionality.
Solution Approach 2:
The bus bars and star bar are stacked one on top of the other to form a compact bar stack configuration. This nested stacking arrangement allows the terminal components to be space-efficiently organized in a vertical hierarchy, minimizing the installation footprint while preserving all electrical connection pathways.
2Productivity
If more parallel current paths are implemented, then current distribution capability is improved, but the number of components and production costs increase
Solution Approach 1:
At least n≥4 parallel current output elements are integrated into each bus bar, and the star bar consolidates at least 3n current input elements. This merging approach provides enhanced current distribution capability through multiple parallel paths while reducing the total component count and simplifying production compared to implementing separate connectors for each path.
Solution Approach 2:
The bus bars and star bar serve multiple functions simultaneously: they provide electrical connection, enable current distribution through parallel paths, and offer structural support. This multi-functionality allows the terminal to achieve high productivity in current distribution without proportionally increasing component count or production complexity.
Data Source
AI summary
A high-voltage terminal for a stator, including: —three bus bars for electrically connecting the HV terminal to power electronics; and —a star bar; wherein each of the three bus bars has a current input element and at least n parallel current output elements, and the star bar has at least 3n current input elements, n being greater than or equal to 4, and wherein, within the HV terminal, the bars are stacked one on top of the other to form a bar stack and are arranged such that they are electrically insulated from one another by at least one plastics element, more particularly are electrically insulated from one another in a plastics element, and preferably are embedded therein.