BLDC Motor Terminal Housing Rigidity and Assembly
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Solution Overview
Problem
The existing terminal housing connection structure in BLDC motors suffers from reduced rigidity and potential functional damage due to gaps that increase during assembly, leading to vibration weaknesses and assembly challenges.
Innovation Solution
A terminal connection structure featuring a coiled insulator body with a terminal housing assembly unit, including a guide plate and protruded hook for adjustable fitting, and a taper-shaped inner wall to enhance the moving interval and power transmission, allowing for improved assembly and increased rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal housing connection unit and terminal housing are combined with a gap, then the terminal housing can be easily separated for power-on assembly, but the rigidity of the housing drops and causes function loss or damage due to vibration
Solution Approach 1:
The terminal housing connection structure is divided into separate components: terminal housing connection unit, terminal housing, and insulator. These segments can be assembled and disassembled independently, allowing easy separation for power-on assembly while maintaining structural integrity through precise connection interfaces
Solution Approach 2:
The terminal housing connection unit is integrally combined with the insulator, forming a nested structure where the connection unit is embedded within the insulator body. This nesting provides structural support and maintains rigidity while allowing the terminal housing to be separately assembled and disassembled
2Ease of manufacture
If the gap between terminal housing connection unit and terminal housing is increased, then assembly is easier, but the housing becomes weaker against vibration
Solution Approach 1:
The terminal housing connection unit is pre-integrated with the insulator during manufacturing, creating a stable base structure before the terminal housing is assembled. This preliminary integration ensures proper positioning and reduces assembly difficulty while maintaining vibration resistance through the rigid insulator connection
3Productivity
If the terminal housing is made removable for power supply assembly, then productivity improves, but the structural integrity and rigidity are compromised
Solution Approach 1:
The housing structure is segmented into removable terminal housing and fixed insulator connection unit, enabling selective assembly and disassembly for productivity improvement while the fixed insulator portion maintains overall structural integrity
Solution Approach 2:
The terminal housing connection unit is merged with the insulator as an integral component, ensuring that the removable portion (terminal housing) does not compromise the structural integrity of the fixed portion (insulator connection unit), thus maintaining stability while enabling easy assembly
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Disclosed terminal housing connection structure for the motor is comprising: an insulator body; a terminal housing assembly unit protruding circumferentially and being combined with the insulator body integrally; a terminal housing having sliding hook combination with the terminal housing assembly unit, thus being capable of supplying a power to the motor; a fixing unit locking the position of terminal housing in the terminal housing assembly unit and comparting the coil unit of the insulator body with the terminal housing.