Modular Hub Motor Wire Outlet Assembly for Precise Sealed Alignment
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Solution Overview
Problem
The existing wire assembly structure for hub motors in electrically-assisted bicycles faces difficulties in assembly, alignment, waterproofing, and dustproofing, leading to increased space occupation, weight, and reduced safety and service life.
Innovation Solution
A modularized hub motor wire outlet structure with a modularized wire outlet assembly that includes a motor connector and a wire connector, featuring positioning notches and waterproof gaskets, allowing for precise alignment and easy assembly, while enhancing waterproof and dustproof capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wire assembly is arranged to extend through hub axle individually, then connection between control system and electric machine is achieved, but assembly operation becomes difficult and alignment accuracy deteriorates
Solution Approach 1:
The wire outlet assembly is segmented into distinct functional components: a positioning structure with positioning notches for alignment, a sealing structure with waterproof gaskets for protection, and connection terminals for electrical contact. This segmentation allows each component to be optimized independently and assembled in a standardized sequence, improving both assembly ease and alignment accuracy
Solution Approach 2:
The wire outlet assembly serves as an intermediary component between the hub axle and the external wire harness. It provides a pre-assembled interface that simplifies the connection process by combining positioning, sealing, and electrical connection functions into a single modular unit, making assembly operations easier and more precise
2Reliability
If wire assembly structure is traditional and non-modularized, then simple structure is maintained, but assembly firmness and alignment accuracy deteriorate
Solution Approach 1:
The wire outlet assembly is divided into modular components including a positioning structure with positioning notches, a sealing structure with waterproof gaskets, and terminal connection parts. This modularized segmentation enables standardized assembly procedures that improve assembly firmness while keeping each individual component relatively simple in structure
Solution Approach 2:
Multiple functions (positioning, sealing, electrical connection) are merged into a single integrated wire outlet assembly unit. This consolidation improves assembly firmness by creating a unified structure with multiple functional features, while the internal modular design prevents excessive overall complexity
3Reliability
If waterproof and dustproof operations are not performed effectively, then assembly simplicity is maintained, but operation safety and service life deteriorate
Solution Approach 1:
Waterproof gaskets are pre-installed into grooves within the wire outlet assembly during manufacturing, and sealing structures are pre-configured before final assembly. This preliminary action ensures waterproof and dustproof protection is built into the structure, improving operation safety without requiring complex sealing operations during field assembly
Solution Approach 2:
The wire outlet assembly acts as an intermediary barrier between the internal hub motor components and the external environment. It incorporates integrated sealing structures and waterproof gaskets that automatically provide protection when assembled, enhancing operation safety while maintaining assembly simplicity through its pre-engineered design
4Ease of operation
If area occupied by wire assembly is increased for assembly convenience, then assembly operation space is improved, but weight of electrically-assisted bicycle increases
Solution Approach 1:
Multiple functions (positioning, sealing, electrical connection, wire routing) are merged into a single compact wire outlet assembly. This consolidation reduces the total space and weight required compared to separate components, while the integrated design maintains ease of operation through its unified structure and standardized interface
Data Source
AI summary
A hub motor wire outlet structure includes a hub motor and a wire outlet assembly. The wire outlet assembly includes a motor connector and a wire connector, and a load-side circuit board of the motor connector and a power-side circuit board of the wire connector are interconnectable through a plurality of terminal pin connecting pillars so as to form a modularized structure. As such, the firmness and alignment accuracy of the assembly can be effectively improved, making it easy to assemble during mounting, enhance operation safety, and also reduce the area occupied by the entire wire assembly.