Stator Bus Carrier Bonding Structure for Vibration-Stable Busbars
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Relative movements, such as vibration, cause bus bars in electric motors to become dislodged or loose within the housing, leading to potential disconnection issues.
Innovation Solution
A system for connecting a stator assembly to an electric motor using a bus carrier that defines either an opening or a projection, with a bonding medium adhering the projection within the opening to secure the bus bar in place, utilizing features like ribs, posts, and fixation brackets to prevent relative movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bus bars are simply placed in the housing without additional securing mechanisms, then the device complexity is reduced, but the bus bars become dislodged or loose due to vibration and relative movements
Solution Approach 1:
The bus carrier is nested within the housing, with the projection extending into the opening defined by the housing. The bonding medium is then applied to secure the bus carrier in place, creating a nested arrangement that stabilizes the bus bar connection without requiring external mounting structures.
Solution Approach 2:
A bonding medium is introduced as an intermediary substance between the projection of the bus carrier and the housing opening. This bonding medium adheres the two components together, preventing relative movement and dislodgment while maintaining a relatively simple overall structure.
2Reliability
If bonding medium is applied to secure the bus carrier in the housing, then the bus bar connection stability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The projection is pre-formed on the bus carrier before assembly, allowing it to extend into the housing opening and provide a ready surface for bonding medium application. This preliminary structuring simplifies the overall assembly process by integrating the mounting feature into the bus carrier itself.
3Stability of the object's composition
If projections and openings are used to secure the bus carrier, then the bus bar position stability is improved, but the device complexity increases due to additional structural features
Solution Approach 1:
Instead of making the entire bus carrier or housing complex, the invention applies local structural features: a projection is added only to the bus carrier where needed for mounting, and a corresponding opening is created only in the housing where the bus carrier needs to be secured. This localized approach provides stability without overall complexity.
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
The system effectively reduces relative movement between the bus bar and housing, ensuring secure and stable connections by using bonding media and structural features to maintain the bus bar's position, thereby preventing dislodgment.
Implementation Method 1
A bonding medium is in the opening and in contact with the projection and a surface defining the opening to adhere the projection within the opening
Data Source
AI summary
A system for connecting a stator assembly to an electric motor includes a housing of the electric motor defining one of an opening or a projection. A plurality of windings is located within the housing. At least one bus bar is in conductive communication with the plurality of windings. A bus carrier supports the at least one bus bar. The bus carrier defines the other of the opening or the projection, and the projection extends into the opening. A bonding medium is in the opening and in contact with the projection and a surface defining the opening to adhere the projection within the opening.