Electric Motor Bearing Shield Plug Coupling for Automated Assembly
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Solution Overview
Problem
The manual crimping process for connecting flexible brake connection cables in permanent magnet electric motors is prone to errors and lacks reproducibility, requiring manual assembly and increasing assembly effort.
Innovation Solution
An automated arrangement featuring plug components on the end shield of the electric motor, allowing for the electrical coupling of built-in components, such as brakes or transmitters, directly to the end shield, eliminating the need for crimp connections and enabling automatic assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual crimping process is used for connecting brake connection cables, then flexible cable connection is achieved, but assembly effort increases and reproducibility of quality deteriorates
Solution Approach 1:
The patent replaces the manual mechanical crimping process with an automated plug connection system. The plug component with contact elements eliminates the need for manual crimping operations, allowing automated assembly while maintaining flexible cable connections. This substitution of mechanical assembly methods resolves the contradiction between operational flexibility and assembly productivity.
Solution Approach 2:
The plug component is pre-assembled with contact elements and cable connections prepared in advance. The brake connection cable is pre-connected to the plug component before installation on the bearing plate, enabling automated assembly processes. This preliminary preparation eliminates time-consuming manual crimping during final assembly, improving productivity while maintaining connection flexibility.
2Ease of manufacture
If manual crimping process is used for connecting brake connection cables, then cable connection is achieved, but manufacturing precision and quality reproducibility deteriorate
Solution Approach 1:
The patent replaces the manual crimping process with an automated plug connection system featuring standardized contact elements. The plug component with predefined contact geometry eliminates variability in crimp quality, ensuring consistent electrical connections. This mechanical substitution achieves both ease of manufacture and high manufacturing precision through automated, repeatable assembly operations.
Solution Approach 2:
The invention changes the connection parameter from variable manual crimping force to standardized plug insertion force. The contact elements are designed with specific dimensional parameters that ensure consistent electrical contact when the plug is inserted. This parameter standardization improves manufacturing precision and quality reproducibility while maintaining ease of manufacture through automated processes.
3Productivity
If plug components are used for automated coupling, then assembly effort is reduced and automation is enabled, but device complexity increases
Solution Approach 1:
The plug component is designed as a universal connector that can be used across multiple motor series and different built-in components. The standardized contact elements and plug geometry allow the same connector design to serve multiple functions and applications. This universality reduces device complexity by eliminating the need for multiple specialized connectors, while enabling automated assembly through consistent, repeatable coupling operations.
Data Source
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AI summary
The invention relates to an arrangement (12) for an electric motor (10) with at least one electronic component (16) on a bearing shield (22) of the electric motor (10), wherein a first connector component (24) is formed on the bearing shield (22), which corresponds to a second connector component (26) on the component (16), and wherein the first connector component (24) is electrically coupled to a connection component (30) formed on an outer surface (28) of the bearing shield (22). The invention further relates to a method for manufacturing an arrangement (12).