Rotary Machine Stator Bus Bar Arrangement
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Solution Overview
Problem
The existing stators of rotary electric machines in electric vehicles have a heightened upper portion due to the arrangement of bus bars, which narrows occupant and luggage compartment spaces.
Innovation Solution
The bus bars are arranged with first terminal parts on the outside of the stator core in an upper and lower direction and second terminal parts above the stator core in a horizontal direction, with the uppermost first terminal part positioned below the stator core's uppermost part, reducing the overall height of the stator even when the power conversion device is above it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are arranged with terminal parts protruding above the stator to connect coils and power conversion devices, then electrical connectivity is ensured, but the height of the upper portion of the stator is increased
Solution Approach 1:
The bus bars are arranged to extend in multiple directions (radial direction and axial direction) rather than simply protruding upward. The first terminal parts are positioned on the outside of the stator core in the radial direction, while the second terminal parts extend above the stator core in the axial direction, creating a three-dimensional arrangement that reduces the overall height requirement while maintaining electrical connectivity.
Solution Approach 2:
The bus bar structure is divided into multiple segments: the main body extending radially outward, the first terminal parts for coil connection, and the second terminal parts for power conversion device connection. This segmentation allows each part to be optimally positioned in different spatial dimensions, reducing the total height while ensuring all electrical connections are maintained.
2Reliability
If bus bars are arranged to connect terminal parts of coils and power conversion devices, then electrical function is achieved, but occupant space and luggage compartment space are narrowed
Solution Approach 1:
By arranging the bus bars to extend primarily in the radial direction (first terminal parts on the outside of the stator core) rather than exclusively in the axial direction, the design reduces the vertical height occupation. This dimensional redistribution allows more vertical space to be available for occupant and luggage compartments while maintaining all necessary electrical connections through the multi-directional bus bar configuration.
Data Source
AI summary
A stator of a rotary electric machine comprises a stator core, a coil; and a plurality of bus bars. When viewed from a rotational axis direction of the rotary electric machine, the first terminal parts of the plurality of bus bars are arranged next to one another substantially in an upper and lower direction on the outside of the stator core in the radial direction, and the second terminal parts of the plurality of bus bars are arranged next to one another substantially in a horizontal direction above the stator core, and a first terminal part arranged on an uppermost side among the first terminal parts of the plurality of bus bars is arranged to be positioned below an uppermost part of the stator core.