Two-Layer Bus Bar Terminal Structure for Compact Motor Design
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Solution Overview
Problem
The existing deep drawing method for manufacturing motor housings is limited in producing large or complex shapes, resulting in structural weaknesses and inefficient space utilization due to the spatial restrictions and high material wastage in bus bar terminal arrangements.
Innovation Solution
A bus bar with a two-layer terminal structure is designed, where upper and lower terminals are disposed on the bus bar body, connected through holes, and coupled without additional members, enhancing space utilization and simplifying terminal shapes to reduce manufacturing costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the deep drawing method is used to manufacture the housing, then the housing can be produced with simple shape and small size, but it cannot manufacture housing with large size and complicated shape and the housing is weak to radial force
Solution Approach 1:
The housing is divided into two separate parts: a cylindrical body portion and a flange portion. These segments are manufactured separately using suitable processes and then assembled together, allowing each part to be optimized for its specific manufacturing requirements while achieving the overall complicated shape
2Reliability
If terminals are disposed vertically as three layers to consider fusing with coils, then electrical connection is achieved, but the bus bar occupies large space in shaft direction
Solution Approach 1:
The terminal arrangement transitions from a vertical three-layer configuration to a planar configuration where terminals are disposed on the same level as the bus bar body. This dimensional change eliminates the need for vertical stacking, reducing the bus bar's occupancy in the shaft direction while maintaining electrical connection reliability through lateral arrangement
3Reliability
If connecting ends of terminals are formed in hook shapes for coil connection, then electrical connection is achieved, but the connecting ends occupy large space in the motor when viewed from above
Solution Approach 1:
The hook-shaped connecting ends are extracted and replaced with flat terminal ends that make direct contact with the coils. This eliminates the need for complex hook formations, reducing the radial space occupied by terminal connecting ends while maintaining reliable electrical connection through simplified contact geometry
4Adaptability or versatility
If different shapes are generated between terminals for specific connections, then connection functionality is achieved, but the amount of scraps is greatly increased and loss rate of raw material is high
Solution Approach 1:
All terminals are designed with a unified shape and structure that can serve multiple connection functions. This standardized design allows terminals to be interchangeably connected to different coils without requiring shape variations, significantly reducing material scraps and raw material loss rate while maintaining the necessary connection functionality
Data Source
AI summary
An embodiment relates to a bus bar comprising a main body; an upper terminal which is disposed on an upper surface of the main body; and a lower terminal which is disposed on a lower surface of the main body, wherein the upper terminal includes a first upper terminal and a second upper terminal, the lower terminal includes a first lower terminal, the main body includes a first hole and a second hole which penetrate the main body, and the first lower terminal has one end which is connected to the first upper terminal through the first hole and the other end which is connected to the second upper terminal through the second hole and to a motor comprising the same. According to this, space utilization inside the motor can be improved.