Stator Coil-End Support Structure for Stable Busbar Positioning
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Solution Overview
Problem
In stators with busbars positioned on the outer peripheral side of coil end portions, the busbar position can be displaced in the radial direction during connection, leading to instability and potential electrical issues.
Innovation Solution
The stator design includes a stator core with slots for multi-phase coils, where coil ends protrude radially and are bent to form axial and radial support portions, allowing busbars to be securely positioned and connected, preventing displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar is positioned on the outer peripheral side of the coil end portion, then the connection between the coil and external terminal is achieved, but the busbar position may be displaced in the radial direction during connection
Solution Approach 1:
The coil end is pre-formed with a support portion that protrudes in the radial direction before the busbar connection process. This preliminary structural preparation provides a predetermined positioning feature that guides and stabilizes the busbar during connection, preventing radial displacement and ensuring accurate positioning without requiring additional positioning mechanisms during assembly
Solution Approach 2:
The support portion of the coil end acts as an intermediary element between the busbar and the coil body. It provides a dedicated interface that facilitates stable connection while maintaining precise radial positioning. The support portion transfers and distributes mechanical forces, ensuring the busbar remains securely positioned during the connection process
Data Source
AI summary
A stator includes a stator core, three-phase coils, three external terminals, and three busbars. Each of the three-phase coils has a first coil end protruding from the radially outermost side of a slot to a first side in the axial direction of the stator core. Each of the three bus bars includes a busbar body portion extending in a circumferential direction of the stator core, a busbar connection portion extending toward the first side in the axial direction, and an external terminal connection portion extending outward in the radial direction and connected to the external terminal. The first coil end extends in the radial direction through between the busbar body portion and the stator core in the axial direction, extends toward the first side in the axial direction on a radially outer side of the busbar body portion, and has a tip connected to the busbar connection portion from the radially outer side.