Stator Winding Connection Slots That Eliminate Motor Busbars
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing method for connecting stator windings in motors involves complex processing steps and high costs due to the use of busbars, crimping, welding, and injection molding, which complicates the connection structure and increases material costs.
Innovation Solution
A stator assembly with a simplified connection structure that eliminates the need for busbars by using a main control board with spaced connection slots and conductive portions for direct electrical connection of wiring terminals, supported by pins if necessary, and a manufacturing method involving insert molding and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars and insulating brackets are used to connect stator windings with multiple crimping and welding processes, then reliable electrical connection is achieved, but processing complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges the functions of the insulating bracket and busbar into a single integrated main control board. The connection slots are formed directly on the main control board with conductive portions that serve both as electrical connection terminals and as integrated busbars, eliminating the need for separate busbar components and simplifying the overall connection structure while maintaining reliable electrical connections.
Solution Approach 2:
The main control board is designed to perform multiple functions: it serves as the control circuit board, provides structural support through integrated connection slots, and acts as the electrical connection terminal with conductive portions. This multi-functional design replaces the traditional separate components (insulating bracket + busbar + control board), reducing assembly steps and manufacturing complexity.
2Reliability
If traditional busbar and bracket connection method is used, then stable electrical connection is achieved, but manufacturing cost and processing time increase
Solution Approach 1:
By integrating the connection slots and conductive portions directly into the main control board during its fabrication process, the patent eliminates the need for separate busbar attachment operations. The wiring terminals are directly mounted onto the integrated connection slots, reducing the number of assembly steps and improving manufacturing efficiency while maintaining stable electrical connections.
Solution Approach 2:
The connection slots with conductive portions are pre-formed on the main control board during its manufacturing process before assembly. This preliminary preparation of the connection interface allows for faster and simpler assembly of the wiring terminals, improving overall manufacturing efficiency without compromising connection stability.
3Reliability
If multiple components (busbars, brackets, insulation material) are used for wiring connection, then reliable electrical connection is achieved, but material cost increases
Solution Approach 1:
The patent combines the functions of multiple separate components (busbars, insulating brackets, and control board) into a single integrated main control board. The conductive portions formed on the main control board replace traditional busbars, while the connection slots provide both structural support and electrical connection functionality, eliminating the need for separate insulating brackets and reducing overall material cost.
Solution Approach 2:
The main control board is designed to perform multiple functions simultaneously: it provides the control circuitry, structural support through integrated connection slots, and electrical connection terminals via conductive portions. This multi-functional design eliminates the need for separate dedicated components, reducing material usage and cost while maintaining reliable electrical connections.
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 simplified connection structure reduces processing complexity and costs, enhances installation ease, and improves production efficiency of motors.
Implementation Method 1
electrically connecting the wiring terminal to a first conductive portion on an inner wall of the connection slot by welding
Implementation Method 2
performing insert molding on a single stator core to form a stator core with an insulating frame
Data Source
AI summary
A stator assembly, a motor, and a manufacturing method for the stator assembly are disclosed. The stator assembly includes a stator and a main control board arranged at an axial outer end of the stator. The stator is spliced together by a plurality of stator cores. A stator winding is wound around the stator core. The stator winding has a wring terminal. The main control board has at least two spaced-apart connection slots. At least a portion of an inner circumferential wall of the connection slot is provided with a first conductive portion. Each wiring terminal is disposed in a corresponding connection slot and electrically connected to the first conductive portion. The winding connection structure provides a simple process and is easy to install.