Hermetic Motor Winding Direct Coupling to Protector
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Solution Overview
Problem
Hermetic motors with lead wires introduce potential points of failure and increase manufacturing costs due to additional connection steps, which are not effectively addressed by existing connection methods.
Innovation Solution
Directly coupling substantially solid winding wires to the on-winding motor protector contacts without lead wires, using methods such as crimping, welding, or splice terminals, to eliminate electrical connections and reduce material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wires are used to connect winding wires to motor protector contacts, then the connection is more flexible and easier to manufacture, but the reliability decreases due to additional potential points of failure
Solution Approach 1:
The patent removes lead wires from the motor assembly, extracting the source of additional failure points. By directly coupling winding wires to motor protector contacts without intermediate lead wires, the invention eliminates the reliability issues associated with extra connection points while maintaining manufacturing feasibility through direct installation methods.
Solution Approach 2:
The patent merges the winding wire connection directly to the motor protector contact, combining what were previously separate components (winding wire, lead wire, motor protector contact) into a direct integration. This reduces the number of interfaces and potential failure points while simplifying the overall connection structure.
2Ease of manufacture
If lead wires are used to connect winding wires to motor protector contacts, then the connection flexibility is improved, but the manufacturing cost increases due to additional steps
Solution Approach 1:
The patent removes lead wires from the bill of materials, eliminating the material cost associated with purchasing and inventorying these components. By extracting this unnecessary intermediate component, the invention reduces material costs while maintaining manufacturing capability through direct wire-to-contact coupling methods.
Solution Approach 2:
The patent discards the lead wire component entirely from the manufacturing process, eliminating the associated material costs, handling requirements, and assembly steps. This discarding of redundant material directly reduces both material costs and manufacturing complexity.
3Adaptability or versatility
If lead wires are used to connect winding wires to motor protector contacts, then the installation flexibility is improved, but the number of electrical connections increases
Solution Approach 1:
The patent removes lead wires from the electrical connection path, extracting the source of additional connection points. By directly coupling winding wires to motor protector contacts, the invention reduces the total number of electrical connections from multiple interfaces (winding-to-lead, lead-to-connector, connector-to-contact) to a single direct connection.
Solution Approach 2:
The patent merges multiple connection steps into a single direct coupling operation, combining the functions of lead wire attachment, connector attachment, and contact connection into one integrated winding-to-contact coupling, thereby reducing the total number of connections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the reliability of hermetic motors by reducing electrical connections and lowering manufacturing costs by eliminating lead wires and associated connection complexities.
Implementation Method 1
using methods such as crimping, welding, or splice terminals
Data Source
AI summary
A hermetic motor includes a stator having at least one winding formed by a winding wire, and an on-winding motor protector having at least one contact. To improve the reliability and reduce the cost of the hermetic motor, the winding wire is directly coupled (without a lead wire) to the motor protector contact. Additionally, a common wire extending from the motor protector to a cluster block (if applicable) can be the same type of wire as the winding wire.