Stator Bus Bar Layout for Fewer Segment Conductor Types
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Solution Overview
Problem
The increasing number of kinds of segment conductors in stator coils for rotary electric machines leads to higher production costs, necessitating a reduction in the variety of segment conductors to decrease costs.
Innovation Solution
The stator design incorporates a bus bar unit with bus bar end portions welded to segment conductors, where at least one bus bar end portion is located on the inner side of the stator core in the radial direction, promoting commonality among segment coils and reducing the number of kinds of segment conductors needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the variety of segment conductors is increased to improve stator coil performance, then the performance is improved, but the production cost increases
Solution Approach 1:
The patent applies universality by designing a standardized bus bar structure that can be used across different stator coil configurations. The bus bar includes a common bus bar body with multiple bus bar terminals that can connect to different segment conductors, allowing a single standardized component to serve multiple functions and reduce the variety of unique segment conductor designs needed.
Solution Approach 2:
The patent segments the bus bar into a modular structure with a bus bar body and multiple detachable bus bar terminals. This segmentation allows for standardized manufacturing of the main bus bar body while enabling flexibility in connecting different segment conductors through interchangeable terminals, thus reducing overall production complexity and cost.
2Ease of manufacture
If the number of kinds of segment conductors is reduced to decrease cost, then the production cost decreases, but the assembly complexity may increase
Solution Approach 1:
The bus bar is segmented into a main body and separate terminals, allowing standardized mass production of the body while maintaining assembly flexibility through interchangeable terminals. This reduces the number of unique component types needed while keeping assembly straightforward.
Solution Approach 2:
The bus bar acts as an intermediary component that standardizes the connection interface between power/neutral points and segment conductors. By providing a unified connection mechanism through the bus bar terminals, it simplifies assembly even when working with fewer kinds of segment conductors.
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 configuration decreases the variety of segment conductors, thereby lowering the overall cost of the stator while maintaining effective assembly and performance.
Implementation Method 1
The power bus bar includes a bus bar end portion welded to a joint end portion of one of the segment conductors that constitutes the power point of the stator winding. The neutral bus bar includes a bus bar end portion welded to a joint end portion of one of the segment conductors that constitutes the neutral point of the stator winding.
Data Source
AI summary
A stator for a rotary electric machine includes a stator core, a stator winding, a power bus bar, and a neutral bus bar. The stator core includes slots. The stator winding includes segment conductors inserted in the slots. The stator winding includes a power point and a neutral point. The power bus bar includes a bus bar end portion welded to a joint end portion of the segment conductor constituting the power point. The neutral bus bar includes a bus bar end portion welded to a joint end portion of the segment conductor constituting the neutral point. One or each of the respective bus bar end portions of the power bus bar and the neutral bus bar is located on an inner side of the joint end portion of the segment conductor to which the one or each of the bus bar end portions is welded.