Lead Sheath Assembly with Integrated Jumper Box
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Solution Overview
Problem
Existing lead sheath assemblies for motors are complex, difficult to install, unreliable, and lack protective measures, leading to potential safety issues and reduced stability due to loose connectors and external control requirements.
Innovation Solution
A lead sheath assembly with a jumper box and connecting terminal, where external wires are injection molded and baffle plates secure the jumper box, allowing for simple installation and function conversion, and a motor design incorporating this assembly with a microprocessor unit and conductive connectors for enhanced reliability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a connector is used to connect external wires to the control board, then the motor can be connected to external applications, but the assembly becomes complex and the installation becomes troublesome
Solution Approach 1:
The patent integrates the connector directly into the lead sheath assembly by molding the connector body as an integral part of the lead sheath structure. This merging of the connector with the lead sheath eliminates separate components and simplifies the overall assembly, while still providing the necessary connection capability for motor function switching.
2Adaptability or versatility
If a connector is used for external connection, then the motor can switch functions, but the reliability decreases due to loose installation
Solution Approach 1:
The connector body is molded as an integral part of the lead sheath, creating a unified structure that eliminates loose connections. The baffle plate further secures the connector in place, preventing displacement and ensuring stable, reliable installation while maintaining function switching capability through the connector ports.
Solution Approach 2:
The baffle plate is pre-installed on the lead sheath before the connector is attached. This preliminary action creates a secure mounting structure that prevents the connector from becoming loose during operation, thereby improving reliability before the actual connection is made.
3Ease of operation
If the connector port is exposed for connection, then external applications can be connected, but the port is easily polluted or damaged in nonuse state
Solution Approach 1:
The cover is designed to be movable, allowing it to be opened when connection is needed and closed when not in use. This dynamic structure provides protection for the connector port during storage and transport while maintaining easy accessibility during operation, thereby reducing pollution and damage risks.
4Adaptability or versatility
If multiple components are used for connection, then connection functionality is achieved, but production costs increase
Solution Approach 1:
The connector body is molded as an integral part of the lead sheath using injection molding technology. This merging of components eliminates the need for separate connector parts, reducing assembly steps and manufacturing complexity while maintaining full connection functionality, thereby lowering production costs.
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
The solution simplifies motor function conversion, improves installation reliability, reduces production costs, and enhances safety by stabilizing the jumper box and enabling easy connection to external applications.
Implementation Method 1
the lead sheath is disposed on an outer surface of the jumper box by injection molding
Data Source
AI summary
A lead sheath assembly, including a lead sheath; a plurality of external wires; a jumper box; and a connecting terminal. The lead sheath includes a cavity. The jumper box includes: a plurality of through holes, a front end including a front interface, and a rear end including a rear interface. The external wires are mounted on the lead sheath. The jumper box is disposed in the cavity. The connecting terminal is disposed in the through hole.