Integrated Power Terminal Pin for Motor Assembly
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Solution Overview
Problem
The existing power terminal and pin structure in motors is complex, leading to increased production costs and reduced productivity due to separate manufacturing and assembly processes, and difficulty in achieving true position geometric tolerance, which also results in vibration and noise issues during motor rotation.
Innovation Solution
A power terminal with a pin portion integrally formed, including a power connection part and a first connection part, which is coupled to a stator core with a skew-type design, featuring a cylindrical shape and protrusions for secure attachment to the insulator and housing, simplifying assembly and ensuring structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the power terminal and pin are implemented as separated structures and coupled by fusing method, then the power terminal can be manufactured independently, but the manufacturing process becomes complicated and production costs increase
Solution Approach 1:
The patent combines the power terminal and pin into a single integrated component. The pin is formed as an integral part of the power terminal body, eliminating the need for separate manufacturing and fusing processes. This merging approach maintains independent manufacturability while significantly simplifying the overall assembly process and reducing production costs.
2Reliability
If multiple separate components are assembled and fused, then functional requirements are met, but the number of processes increases and productivity is degraded
Solution Approach 1:
The power terminal and pin are merged into a single integrated component that can be manufactured in one process. This eliminates multiple assembly steps including separate pin insertion, fusing operations, and wire attachment processes, thereby significantly improving productivity while maintaining all necessary functional requirements for electrical connection and mechanical support.
Solution Approach 2:
The pin is pre-formed as an integral part of the power terminal during the initial manufacturing process, rather than being added as a separate component during assembly. This preliminary action approach ensures that the pin is already in its final position and configuration before the power terminal is installed, eliminating subsequent assembly operations and improving production efficiency.
3Adaptability or versatility
If the power terminal and pin are separate structures, then manufacturing flexibility is maintained, but true position geometric tolerance is difficult to satisfy
Solution Approach 1:
By merging the pin and power terminal into a single integrated component, the patent ensures that the pin's position relative to the power terminal is precisely controlled during manufacturing. This eliminates positioning errors that would occur during separate assembly operations, making it easy to satisfy true position geometric tolerance requirements while maintaining manufacturing flexibility through the integrated design.
4Ease of manufacture
If conventional separate structure is used, then component independence is achieved, but structural stability and vibration prevention are insufficient
Solution Approach 1:
The integration of the pin as an integral part of the power terminal creates a unified structure with improved structural stability. This merged design eliminates gaps and weak connection points between separate components, providing better rigidity and resistance to vibration during motor operation, while still allowing for independent manufacturing of the integrated assembly.
Data Source
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AI summary
An embodiment relates to a power terminal and a motor including the same, the power terminal comprising: a body; a pin portion extending upward from the body; a coupling portion formed at one end of the body and coupled to an end of a coil; a first protrusion protruding downward from the body; and a second protrusion protruding downward from the body, wherein the second protrusion is arranged to be spaced inward or outward form the body. As a result, the power terminal can improve the productivity through process simplification while satisfying a true position geometric tolerance.