Motor
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Solution Overview
Problem
Conventional motor designs face issues with current leakage due to exposed stator coil cross-sections and structural interference in miniaturized motors, leading to poor performance and efficiency.
Innovation Solution
A motor design incorporating a power connector with a lead wire, fork terminal, and housing that accommodates the lead wire and fork terminal, featuring a clamping portion, fork portion, and elastic contact to prevent coil exposure and minimize coupling structure size, thereby increasing the creeping distance and reducing current leakage and structural interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional mag-mate terminal is used without additional housing, then the structure is simple, but the cross section of the stator coil is exposed and current leakage occurs
Solution Approach 1:
The housing integrates multiple functions: it covers the exposed coil cross-section to prevent current leakage, accommodates the fork terminal and lead wire, and provides structural support. This merging of functions into a single component achieves reliability improvement without proportionally increasing complexity.
Solution Approach 2:
The housing acts as an intermediary component between the external environment and the electrical components (coil, fork terminal, lead wire). It provides physical protection and electrical insulation, mediating the interaction between the power connector elements and the external case, thereby preventing current leakage.
2Ease of operation
If a fork terminal with a bending portion is used, then connection flexibility is improved, but the size of the outer case increases due to structural interference
Solution Approach 1:
The fork terminal is divided into distinct functional segments: a clamping portion for securing the lead wire and a fork portion for electrical connection. This segmentation allows each part to perform its function efficiently while minimizing the overall space required, eliminating the need for bulky bending portions.
Solution Approach 2:
The fork terminal extends in a direction parallel to the rotation axis of the rotor, utilizing the vertical dimension rather than requiring lateral space for bending portions. This dimensional reorientation allows connection flexibility to be achieved without increasing the horizontal footprint of the motor.
3Stability of the object's composition
If the power connector structure is enlarged to accommodate bending portions, then connection stability is improved, but mechanism interference occurs in narrow spaces
Solution Approach 1:
The housing combines the functions of structural support, electrical insulation, and component accommodation into a single integrated element. This merging provides connection stability through the housing's rigid structure without requiring additional separate components for support and insulation.
Solution Approach 2:
The housing serves multiple purposes simultaneously: it provides mechanical support for the fork terminal and lead wire, acts as an electrical insulator to prevent current leakage, and covers the coil cross-section. This multi-functionality achieves connection stability without increasing device complexity.
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 design effectively prevents current leakage and minimizes structural interference in narrow spaces, enhancing motor performance and efficiency by maintaining a safe distance between the coil and outer case while reducing the width of the power connector.
Implementation Method 1
an elastic contact portion configured to be in elastic contact with the fork portion
Implementation Method 2
a clamping portion configured to compress the end of the lead wire
Implementation Method 3
A motor is a device that converts electromagnetic energy into kinetic energy to obtain power
Data Source
AI summary
Disclosed herein is a motor including a power connector capable of preventing current leakage to the outer case and structural interference with the outer case. The motor includes a stator provided with an insulator, a rotor configured to be rotated against the stator, a power connection portion provided in the insulator, and configured to support an end of a coil wound around the stator and configured to accommodate a mag-mate terminal, and a power connector coupled to the power connection portion to connect an external power source to the coil, wherein the power connector includes a lead wire, a fork terminal coupled to an end of the lead wire to electrically connect the lead wire to the coil and a housing configured to accommodate the end of the lead wire and the fork terminal and coupled to the power connection portion.