Integrated Bus Bar Terminal Block Assembly for Motor Connections
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Solution Overview
Problem
Conventional terminal block assemblies for motor wire connections are complex and require numerous components, making the assembly process cumbersome due to the need for multiple fastening points and pressing elements to secure components against vibrations.
Innovation Solution
A simplified terminal block assembly with integrated bus bar bodies, terminal connectors, and coil connectors that use bent metal pieces and anti-movement slits and stoppers to securely position and connect components without additional pressing elements, reducing the number of components and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional terminal block uses a cover with pressing elements to secure multiple components against vibrations, then the connection stability is improved, but the device complexity and number of components increase
Solution Approach 1:
The bus bar body is integrated with the terminal connector and coil connector into a single unified component. This merging eliminates the need for separate pressing elements and covers, as the integrated structure inherently maintains stable connections while reducing the total number of parts
Solution Approach 2:
The bus bar body's own structure provides the securing function through its bent shape that contacts and stabilizes the terminal connector and coil connector. The component serves itself by using its geometric configuration rather than requiring external fastening elements
2Reliability
If multiple fastening members are used to secure components at multiple fastening points, then the connection reliability is improved, but the assembling process becomes more complicated and time-consuming
Solution Approach 1:
Multiple fastening functions are merged into the single integrated bus bar body structure. The bent portions of the bus bar body simultaneously secure both the terminal connector and coil connector, eliminating the need for multiple separate fastening operations and improving assembly efficiency
Solution Approach 2:
The bus bar body is pre-formed with specific bent shapes during manufacturing that enable it to automatically contact and secure the connectors upon assembly. This preliminary shaping eliminates the need for complex fastening operations during the assembly process
3Stability of the object's composition
If separate pressing elements are used to hold components in close contact, then the stability against vibrations is improved, but the number of components and manufacturing complexity increase
Solution Approach 1:
The bus bar body's bent shape creates self-contact with the terminal connector and coil connector, providing inherent stability without requiring additional pressing elements. The geometry of the bus bar body itself provides the securing mechanism
Solution Approach 2:
The bus bar body utilizes flexible bent portions that can elastically contact and adapt to the connectors, providing stable mechanical connection through the flexibility of its own structure rather than rigid fastening elements
Data Source
AI summary
A terminal block assembly for wire connection of a motor, which includes: a terminal block body; one or more bus bar supports which are formed on the terminal block body; one or more bus bar bodies which have bent shapes corresponding to outer surfaces of the bus bar supports and are rested on the terminal block body or the bus bar supports; one or more terminal connectors which are formed at one ends of the bus bar bodies and are held in contact with one or more connector terminals; and one or more coil connectors which are formed at the other ends of the bus bar bodies and are connected to one or more coils of a motor.