Brushless Motor Terminal Assembly for Flexible Customer Interfaces
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Solution Overview
Problem
Conventional brushless motors face challenges in efficiently and cost-effectively adapting to varying customer interface specifications due to the need for multiple components and complex terminal configurations, which increases handling complexity and costs.
Innovation Solution
A brushless motor design featuring three busbars with output terminals extending axially, a holder portion for the busbars, and a compatible component with a connector portion and insulating lid, allowing for multiple terminal configurations that can be easily swapped to meet customer demands without increasing the number of separate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a connector is configured as a separate retrofittable component from the brush holder, then the terminal configuration can be changed to meet customer specifications, but the number of components increases and handling complexity increases
Solution Approach 1:
The patent combines the connector and brush holder into a single integrated component called a 'compatible component'. The connector portion is formed as an integral part of the brush holder, eliminating the need for separate assembly or retrofitting. This merging maintains adaptability through design variations while reducing the number of discrete components and simplifying handling.
Solution Approach 2:
The brush holder is designed with multi-functionality by incorporating both the brush holder function and connector function into a single component. The compatible component serves dual purposes: holding the brush segments and providing the electrical connector interface, thereby reducing component count while maintaining configuration flexibility through different design variants.
2Adaptability or versatility
If multiple separate components are used to enable terminal configuration changes, then customer interface specifications can be met, but costs and handling efficiency deteriorate
Solution Approach 1:
By merging the connector and brush holder into one integrated compatible component, the patent reduces the number of parts that need to be handled during assembly and manufacturing. The single-component design maintains the ability to meet different interface specifications through design variants while improving handling efficiency and reducing manufacturing complexity.
3Adaptability or versatility
If the connector is made as a retrofittable attachment, then terminal configuration can be adapted, but the number of components handled separately from the motor main body increases
Solution Approach 1:
The patent integrates the connector as an inherent part of the brush holder assembly, creating a single compatible component that is handled together with the motor main body. This eliminates the need for separate retrofittable attachments while maintaining terminal configuration flexibility through different design variants of the integrated component.
Data Source
AI summary
A brushless motor where a stator and a rotor are housed in a housing, includes: three busbars located on one end side of the stator in an axial direction, the three busbars connecting three-phase coils provided to the stator on a per-phase basis; three output terminals on the one end side of the busbars, the three output terminals extending in the axial direction while being electrically continuous with the busbars; and a compatible component having: a holder portion placed on the one end side of the busbars in the housing and supported by the housing; and terminals each electrically connected to the respective output terminal and exposed to an outside of the housing. A plurality of types of the compatible components that have the common holder portion and are different in the configuration of the terminals is prepared, and one of the plurality of types is supported by the housing.