Electric Actuator Wiring Connection via Overlapping Case Gaps
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Solution Overview
Problem
The assembly of electric actuators is labor-intensive and costly due to the need for opening cases to connect wiring members, which increases manufacturing costs.
Innovation Solution
The electric actuator design features a motor case and a speed reduction mechanism case with exposed connection portions that overlap when fixed together, allowing for indirect electrical connection without the need for external openings, using plate-shaped connection portions with gaps that guide and secure the wiring members for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wiring members are connected by soldering or fusing inside the case, then electrical connection reliability is improved, but assembly labor and manufacturing cost increase due to required opening portions
Solution Approach 1:
The connection structure is segmented into multiple functional parts: connection portions with gaps on both cases, positioning protrusions, and engagement structures. This segmentation allows the wiring members to be connected through mechanical engagement rather than requiring soldering or fusing operations inside the case, thereby maintaining reliability while simplifying assembly
Solution Approach 2:
The connection portions are pre-formed with gaps and positioning protrusions during case manufacturing. This preliminary action ensures that when the cases are assembled, the wiring members automatically align and connect without requiring additional opening portions or complex assembly operations, reducing both labor and cost
2Ease of operation
If opening portions are provided in cases for wiring connection, then wiring member connection is enabled, but case structure complexity and assembly steps increase
Solution Approach 1:
The connection portions are merged directly into the case structures themselves, eliminating the need for separate opening portions. The gaps and positioning protrusions are integrated features of the cases, allowing wiring connection to occur through the case walls without creating additional structural complexity or assembly steps
3Ease of operation
If connection portions are exposed outside the cases, then wiring member accessibility is improved, but manufacturing precision requirements increase
Solution Approach 1:
Positioning protrusions and engagement structures act as intermediaries between the connection portions and the assembly process. These features guide the alignment of connection portions from both cases, ensuring accurate positioning without requiring extremely tight manufacturing tolerances on the connection portions themselves, thus maintaining accessibility while reducing precision requirements
Data Source
AI summary
An electric actuator includes a first wiring member with a first connection portion exposed to one side in an axial-direction of a first case and a second wiring member with a second connection portion exposed to another side in the axial-direction of a second case, the first and second connection portions each having two opposing portions that respectively oppose in first and second directions with first and second gaps therebetween, the first gap having a narrow portion and a wide portion (larger in the first direction) connected thereto on the other side in the axial-direction, the second gap having a narrow portion and a wide portion (larger in the second direction) connected thereto on the one side in the axial-direction, and the first and second gaps overlapping at least partially when the first and second case are fixed, and the first and second connection portions are electrically connected.