Motor Stator Terminal Structure for Vibration-Resistant Solder Joints
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Solution Overview
Problem
Conventional motor stators in electric vehicles face structural weakness at soldering joints due to downward gravity and motor vibrations, leading to potential failure risks.
Innovation Solution
A motor stator structure with a plastic injection-molded covering member and terminal bracket, incorporating flexible busbars and a floating bracket to support three-phase terminals and busbars, limiting positional deviation and enhancing structural strength through geometric constraints and flexible materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect three-phase terminals to copper wire windings, then electrical connection is achieved, but structural strength at the connection point deteriorates due to poor soldering joint strength under gravity and vibration
Solution Approach 1:
The patent introduces a terminal bracket as an intermediary component between the three-phase terminals and the copper wire windings. This bracket provides a robust mechanical support structure that bears the gravitational load and vibration forces, thereby protecting the soldering joints from excessive stress and improving overall connection reliability.
Solution Approach 2:
The terminal bracket is pre-installed and positioned to provide support before the motor undergoes operation. By establishing the support structure in advance, the soldering joints are protected from the full impact of gravitational and vibrational forces during motor operation, preventing premature failure.
2Strength
If rigid support structure is used to support three-phase terminals, then structural strength is improved, but adaptability to positional deviation deteriorates
Solution Approach 1:
The patent employs a dynamic support mechanism where the terminal bracket allows controlled movement or adjustment of the three-phase terminals within certain limits. This dynamic capability enables the structure to adapt to positional deviations while maintaining sufficient structural strength to support the terminals under normal operating conditions.
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 design reduces the risk of failure at soldering joints by distributing external forces and allowing for positional adjustment of electrical connection sockets, ensuring secure assembly and reduced risk of disconnection.
Implementation Method 1
a plastic injection-molded covering member enclosing the three-phase terminals; a plastic injection-molded terminal bracket connected to the covering member
Implementation Method 2
each of the three-phase busbars includes a flexible material portion, wherein the at least one electrical connection socket is restricted by the floating bracket to float within a predetermined geometric range
Implementation Method 3
the at least one electrical connection socket is restricted by the floating bracket to float within a predetermined geometric range
Data Source
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AI summary
A stator structure (100) includes three-phase terminals (134), a plastic injection-molded covering member (135), a terminal bracket (131), three-phase busbars (151) and a floating bracket (133). The covering member (135) covers the three-phase terminals (134). The terminal bracket (131) connects the covering member (135). The three-phase busbars (151) are connected to the three-phase terminals (134) respectively, and are installed in three separated grooves (137) of the terminal bracket (131). The floating bracket (133) is installed on the terminal bracket (131) and used to accommodate at least one electrical connection socket (142, 144). Each of the three-phase busbars (151) includes a flexible material portion (151d). The electrical connection socket (142, 144) is restricted by the floating bracket (133) to float within a predetermined geometric range.