Integrated Terminal Block for Brushless DC Motor Assembly
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Solution Overview
Problem
Conventional brushless direct current (BLDC) motors face complex manufacturing processes and increased costs due to the fixed coupling of terminals with blocks, which complicates electrical connection to the stator coils and affects the alignment stability of the stator and rotor.
Innovation Solution
A motor design featuring a terminal block with radially extending ribs and a ring portion for easy assembly, where the terminal is integrally formed with the block through insert injection, allowing for secure electrical connection to the stator coils without separate soldering, and a stator with protrusions and grooves for improved alignment with the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is fixed to the block through separate insert injection molding, then the electrical connection is secure, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The terminal and block are merged into a single integrated component. The terminal block includes both the terminal portion for electrical connection and the block portion for structural support, eliminating the need for separate injection molding processes and reducing manufacturing complexity while maintaining secure electrical connections.
Solution Approach 2:
The terminal block serves multiple functions simultaneously: it provides structural support as a block, creates electrical connections through integrated terminals, and offers mounting capabilities through formed ribs and recesses. This multi-functionality reduces the number of separate components needed in the motor assembly.
2Ease of operation
If the shaft support is formed on the upper cover disposed above the block, then the drive shaft can be rotatably coupled, but the alignment of the stator and rotor becomes unstable
Solution Approach 1:
The shaft support function is moved from a separate upper cover component to the terminal block itself. The ring portion of the terminal block provides rotational support for the drive shaft while the terminal block's position on the stator ensures stable alignment. This dimensional reorganization integrates support and alignment functions into a single structurally sound component.
3Manufacturing precision
If the terminal block has a complex structure with frame, ribs, and ring portion, then the alignment and electrical connection are improved, but the manufacturing complexity increases
Solution Approach 1:
The terminal block is designed with pre-formed ribs extending from the frame and a pre-formed ring portion, all created in a single injection molding process. These features are built into the basic structure during manufacturing, eliminating the need for subsequent assembly steps or complex multi-step forming operations, thereby maintaining manufacturing simplicity while achieving precise alignment.
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
Facilitates easy electrical connection of the terminal to the stator coil and enhances the alignment of the stator and rotor, simplifying the manufacturing process and reducing costs while maintaining high efficiency.
Implementation Method 1
the terminal block and the terminal may be integrally formed with each other through insert injection
Data Source
AI summary
Provided are a motor and an electric pump having the same, the motor including: a stator having a center made hollow to vertically pass through its opposite surfaces; a rotor which is disposed to be spaced apart from an inner surface of the stator, and into which a drive shaft is inserted to its center; a terminal block including a frame coupled to an upper side of the stator, ribs extending radially inward from the frame, and a ring portion which is coupled to the ribs and into which an upper side of the drive shaft of the rotor is rotatably inserted; and a terminal coupled to the terminal block and electrically connected to the coil of the stator, wherein the terminal may be easily coupled to the coil of the stator included in the motor, and the stator and the rotor may be easily aligned with each other.