Modular Adapter for Motor Cable Configuration
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Solution Overview
Problem
The manual electrical connection of multi-phase electric motors in star or delta configurations is time-consuming and prone to errors, requiring frequent reconfiguration for changes in circuit or motor direction.
Innovation Solution
A modular adapter connects motor cables to mains cables with fixed assignments, allowing for easy switching between star and delta connections, and includes a housing to secure rotational position, eliminating the need for frequent reconfiguration and reducing error likelihood.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual wiring is performed in the motor terminal box to change circuit configuration or rotation direction, then the motor can be adapted to different applications, but the process is time-consuming and error-prone
Solution Approach 1:
The connection device is divided into separate modules: a motor connection unit with fixed motor cable assignments and a mains connection unit with fixed mains cable assignments. These modules can be independently configured and assembled, eliminating the need for manual rewiring when changing circuit configurations.
Solution Approach 2:
The adapter can be rotated to different positions (first rotational position for clockwise rotation, second rotational position for counterclockwise rotation) to change the motor's rotation direction. This dynamic reconfiguration is achieved simply by rotating the adapter rather than manually rewiring connections.
2Adaptability or versatility
If manual wiring is performed in the motor terminal box, then circuit configuration can be changed, but switching errors frequently occur
Solution Approach 1:
The motor cables are pre-assigned to specific connection points on the motor connection unit, and mains cables are pre-assigned to specific connection points on the mains connection unit. This preliminary configuration eliminates the need for manual wiring decisions, thereby preventing switching errors.
Solution Approach 2:
Instead of manually connecting motor cables to mains cables directly in the terminal box, the invention inverts the approach by using an adapter with fixed assignments that automatically establishes the correct connections based on its rotational position.
3Reliability
If the adapter is designed with fixed assignments to motor and mains cables, then connection errors are reduced, but the device complexity increases
Solution Approach 1:
The adapter serves multiple functions: it provides fixed assignments for motor and mains cables, enables rotation direction control through rotational positioning, and can be configured for different circuit configurations (star or delta connections). This multi-functionality is achieved in a single integrated component rather than multiple separate devices.
4Device complexity
If the adapter housing is designed as a single integrated unit with the motor connection box, then the number of components is reduced, but the adaptability for different wiring configurations decreases
Solution Approach 1:
The adapter's rotational capability provides dynamic reconfiguration options within the integrated housing. By rotating the adapter to different positions, different electrical wiring configurations (star or delta connections) and rotation directions can be achieved without changing the physical structure or adding components.
Data Source
Figure 1~3
Figure 4~7
Figure 8~10
AI summary
The device has a junction box in which motor lines (7) of an electric motor are connected with connecting lines of a power connector. An adapter (10) is arranged between the motor lines and the connecting lines, and is designed as an independent, replaceable connector. The adapter connects a single connecting line of the power connector with a single motor line (7a) of the electric motor. The adapter connects the lines with each other in a predetermined configuration based on its rotational position.