Twist-Bendable Busbar Terminal for Low-Scrap Motor Assembly
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Solution Overview
Problem
Conventional busbar terminals in motors generate a significant amount of scraps during press processing due to their perpendicular design, leading to increased material costs and reduced rigidity during assembly.
Innovation Solution
The connection terminal of the busbar is formed in a twist-bendable shape alongside the body portion, reducing scraps during press processing and enhancing rigidity by twisting across the body portion during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the connection terminal is formed perpendicular to the body portion in conventional design, then electrical connection is achieved, but a significant amount of scraps is generated during press processing
Solution Approach 1:
The connection terminal is repositioned from a perpendicular arrangement to a side-by-side arrangement in the length direction of the body portion. This dimensional reconfiguration allows both the body portion and connection terminal to be formed in a straight line during press processing, significantly reducing material waste and scraps while maintaining electrical connection functionality.
Solution Approach 2:
The terminal design transitions from a symmetric perpendicular structure to an asymmetric linear structure where the connection terminal extends along the length direction of the body portion. This asymmetric arrangement optimizes material utilization during press processing and reduces scraps generation.
2Strength
If the connection terminal is formed perpendicular to the body portion, then assembly is simplified, but rigidity during assembly is reduced
Solution Approach 1:
The connection terminal is designed with a twist-bendable curved shape including multiple bent portions instead of a straight perpendicular structure. This curvature allows the terminal to be twisted and bent in a crossing direction during assembly, enhancing rigidity and structural stability while maintaining ease of assembly through the flexible curved design.
3Loss of substance
If the connection terminal is formed side by side with the body portion in a twist-bendable shape, then scraps are reduced during press processing, but the structure becomes more complex
Solution Approach 1:
The connection terminal is divided into multiple segments including a support portion, first connection portion, first bent portion, and contact portion, each connected through bent lines. This segmentation allows the terminal to be formed in a straight line with the body portion during press processing, reducing scraps while the modular segmented structure maintains manageable complexity.
Data Source
AI summary
The present embodiments relate to a terminal of a busbar and a motor including the same. More specifically, there may be provided a terminal of a busbar that may reduce the amount of scraps generated during press processing as the connection terminal is formed side by side with the body portion in a twist-bendable shape to thereby reduce material costs and may increase rigidity as the connection terminal is twist-bent in a direction of crossing the body portion during assembly, and a motor including the same.