Connector Element Retention via Complementary Geometries
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Solution Overview
Problem
Existing electrical power tools with drive motors require laborious and complicated processes to retain connector elements on the insulating body, either through separate devices for stationary retention or alignment during plastic injection molding.
Innovation Solution
The use of a fastening segment and receptacle with complementary geometrical shapes on the connector element and insulating body, respectively, to securely and simply retain the connector elements, preventing self-actuated detachment and allowing for quick installation of electrically conductive connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connector elements are retained on the insulating body by way of separate devices or alignment during injection molding, then electrical connection is achieved, but the manufacturing process becomes laborious and complicated
Solution Approach 1:
The fastening segment is integrated directly into the connector element, combining the retention function with the connector element itself. This eliminates the need for separate retention devices and simplifies the manufacturing process by reducing the number of components and assembly steps.
Solution Approach 2:
The connector element with the fastening segment performs its own retention function without requiring external retention devices. The fastening segment automatically engages with the receptacle on the insulating body, making the connector element self-retaining and eliminating the need for separate alignment devices during injection molding.
2Reliability
If connector elements are injection-embedded into the insulating body, then retention is achieved, but alignment and positioning become laborious and difficult
Solution Approach 1:
The fastening segment is pre-formed as an integral part of the connector element during connector element manufacturing. This preliminary formation of the fastening segment eliminates the need for complex alignment operations during the injection molding of the insulating body, as the fastening segment is already in its final position and orientation.
Solution Approach 2:
The fastening segment and connector element are merged into a single integrated component. This integration eliminates the need for separate alignment devices and simplifies the manufacturing process by reducing the number of components that require precise alignment during assembly.
3Ease of manufacture
If a simple retention method is used, then manufacturing is simplified, but the connector elements may detach during operation
Solution Approach 1:
The fastening segment and receptacle are designed with complementary asymmetric geometries that prevent self-actuated detachment. The asymmetric shape ensures that the connector element can be easily inserted but cannot accidentally detach during operation, providing both simple manufacturing and secure retention.
Solution Approach 2:
The fastening segment and receptacle feature curved surfaces that facilitate easy insertion while preventing accidental removal. The curved geometry allows for smooth engagement during assembly but creates mechanical interference that prevents detachment during normal operation, achieving both simplicity and reliability.
Data Source
AI summary
An electrical power tool has an electronically commutated drive motor, preferably a direct current motor. The motor includes a stator core equipped with an insulating body, on which core a motor winding is embodied. Also included in the motor is at least one electrically conductive connector element for electrical connection of the motor winding, the connector element being disposed on the insulating body. The connector element has a fastening segment, and a receptacle for reception of the fastening segment is provided on the insulating body. The fastening segment and the receptacle have complementary geometrical shapes that prevent self-actuated detachment of the fastening segment disposed in the receptacle.