Hybrid Cable Terminal Box for Cost-Effective Motor Control
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Solution Overview
Problem
Current connection technologies for controlling electronic motors using single-cable solutions are costly and complex, especially when high protection levels like IPx5+ are required, due to extensive wiring and expensive connector technologies.
Innovation Solution
The integration of printed circuit board technology with pre-assembled hybrid cables, where power, electronics, and communication are combined in a single cable, using contact devices with male and female pins or sockets, and a terminal box system with elastomer plastic molding and crimp sleeves for strain relief and shielding, reduces costs while maintaining high protection levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connector technology with high degree of protection (IPx5+) is used, then protection level is improved, but cost increases significantly
Solution Approach 1:
The connection system is divided into two segments: pre-assembled connectors with basic protection (IP20) and a terminal box assembly that provides the high degree of protection (IPx5+). The terminal box base and cover together form the protective enclosure, while the connectors themselves remain simple and cost-effective. This segmentation allows each component to be optimized independently for its specific function.
Solution Approach 2:
The terminal box base and cover act as an intermediary protective structure that shields the connectors and wiring from environmental factors. Instead of requiring expensive IPx5+ rated connectors, the terminal box assembly provides the necessary protection for the entire connection system, allowing use of cheaper connectors while maintaining overall system protection.
2Reliability
If terminal box technology with extensive wiring is used, then protection level is improved, but complexity and error-proneness increase
Solution Approach 1:
Multiple functions are merged into the terminal box assembly: strain relief, shielding, electrical connection, and environmental protection. The terminal box base integrates socket strips with connection sockets, the cable entry provides strain relief and sealing, and the cover completes the protective enclosure. This consolidation reduces the number of separate components and simplifies installation compared to traditional extensive wiring approaches.
Solution Approach 2:
The connectors are pre-assembled with the single cable before installation into the terminal box. The single cable with integrated connectors is manufactured as a complete assembly, eliminating the need for on-site wiring and connection work. This preliminary assembly reduces installation complexity and minimizes errors during installation.
3Ease of manufacture
If single-cable solutions with hybrid cables are used, then cost is reduced, but protection level deteriorates
Solution Approach 1:
The terminal box assembly serves as an intermediary protective structure that compensates for the lower protection level of the single-cable solution. The terminal box base and cover together provide IPx5+ protection for the entire connection system, including the hybrid cable and connectors, allowing use of cost-effective single-cable technology while maintaining required protection levels.
4Ease of manufacture
If pre-assembled connectors without high protection are used, then cost is reduced, but protection level deteriorates
Solution Approach 1:
The protection function is segmented from the connectors and assigned to the terminal box assembly. The connectors themselves remain simple, unshielded components with basic protection, while the terminal box base and cover provide the high degree of protection (IPx5+) for the entire connection system. This segmentation allows cost-effective connectors to be used while maintaining overall system protection.
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 simplifies the connection process, reduces material costs, and ensures a high degree of protection by using pre-assembled connectors and a terminal box system that securely holds the cables, providing effective strain relief and shielding.
Implementation Method 1
crimped with a crimp sleeve pushed onto the cable jacket and over the flange sleeve
Implementation Method 2
The crimp flange thus formed is inserted into a receptacle with the connecting cable fastened therein
Implementation Method 3
an elastomer plastic molded onto the single cables
Implementation Method 4
the molded head part with the associated receptacle, respectively with the shells forming the shots, cooperating in a sealing manner
Implementation Method 5
Such a shield, which can be in the form of a wire mesh, a stranded network or a metal foil enveloping the conductor, then represents a protective conductor (TE conductor). Such a shield serves to ensure the electromagnetic compatibility (EMC) of the cable.
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to a method for connection for the cost-effective control of an electronic motor (9) by means of single-cable technology having a high protection class, wherein the connector technology which is known per se is combined with the terminal box technology (3) which is known per se, and the single cable (1) is pre-assembled with connectors without a high protection class, and, with the terminal box (3) of the electronic motor (9) open, the connectors (2) are inserted into the associated sockets (4), and the pre-assembled single cable (1) is inlaid into a combined strain relief (11) and earthing shell (5) formed in the terminal box (3), and a terminal box base (3.1) is firmly closed by a terminal box lid (8). The method is characterised in that, by the screwing of the terminal box lid (8) to the terminal box base (3.1), the connectors (2) are held in position in their sockets (4) in the terminal box (3), in that the connection produced by the connectors (2) and sockets (4) takes place in accordance with printed circuit board technology, and in that the single cable (1) is a hybrid cable, in which the power supply, the electronic power supply and the communication are combined in one cable.