Compression-Mount Electrical Connector for Motor Stator Alignment
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Solution Overview
Problem
Conventional multi-position connectors lack precise mounting control to curved surfaces and inside diameters of motor stators, leading to difficulties in automated assembly, transportation, and potential damage during handling.
Innovation Solution
An electrical connector with a housing featuring a radiused reference surface, alignment projection, and compression clips, allowing precise mounting to a radiused surface, such as the inside diameter of a motor stator, with features like registration projections and latching projections for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional multi-position connectors are positioned on the outside of the motor stator, then the connector is easily accessible for assembly, but the positioning is not well controlled and the connector may get damaged during transportation
Solution Approach 1:
The connector is moved from the external surface to the internal diameter of the stator, changing the mounting dimension from outside to inside. This internal positioning provides a controlled reference surface while the compression clips extend outward to maintain accessibility for assembly operations
Solution Approach 2:
Compression mounting clips are introduced as intermediary components that bridge the connector housing and the stator inner diameter. These clips provide secure attachment while maintaining controlled positioning through their engagement with the stator's reference surface
2Manufacturing precision
If the connector is mounted to the inside diameter of the motor stator, then precise positioning and control are achieved, but the mounting structure becomes more complex
Solution Approach 1:
The mounting system is segmented into distinct functional components: the connector housing with integrated compression clips, the stator with reference surfaces and slot openings, and the alignment projections. This segmentation allows each component to be optimized independently while achieving precise overall positioning
Solution Approach 2:
A radiused reference surface is implemented on the stator's inner diameter, matching the curved geometry of the connector housing. This curved surface contact provides stable, precise positioning while the geometry itself simplifies the mounting mechanism by eliminating the need for additional flat surfaces or complex alignment features
3Reliability
If compression clips are used for mounting, then secure engagement and stability are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The compression clips are merged with the connector housing as an integrated assembly, eliminating the need for separate manufacturing and assembly steps for the clips. This integration maintains secure engagement functionality while simplifying the overall manufacturing process by reducing part count and assembly operations
Data Source
AI summary
An electrical connector has a housing with a front surface, a rear surface, and side surfaces. A first wall extends between the front surface, the rear surface and the side surfaces. A second wall extends between the front surface, the rear surface and the side surfaces, the second wall having a radiused reference surface. An alignment projection extends from the radiused reference surface in a direction away from the first wall. Compression clips extend from the side surfaces. The compression clips have bases, beams and a latching projections, with the beams extending at angles relative to the side surfaces.