Integrated Motor Connector for External Control Access
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Solution Overview
Problem
Conventional electric motor configurations with separate user interface boxes and lead assemblies increase component counts, expenses, and complexity, leading to packaging and handling issues, as well as a larger motor envelope.
Innovation Solution
An integrated motor assembly with a controller and modular connector assembly that includes a main electronics board and secondary electronics boards, where the connector extends through a control housing to provide access to control components externally, eliminating the need for a separate user interface box and lead assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate user interface box and lead assembly are used to enable user adjustments to motor operation, then motor control functionality is achieved, but component count increases and system complexity increases
Solution Approach 1:
The patent combines the user interface box and lead assembly functions directly into the motor connector. The connector now integrates both electrical connection capabilities and user interface functionality, allowing user adjustments to be made directly at the motor location without requiring separate external components. This merging eliminates the need for additional external user interface boxes and lead assemblies.
Solution Approach 2:
The motor connector is designed to perform multiple functions: it provides electrical power and control signals to the motor while simultaneously serving as the user interface for adjusting motor operation. The connector includes integrated controls that allow users to modify motor parameters directly at the connection point, making the connector a universal component that handles both power transmission and user interaction.
2Adaptability or versatility
If a separate user interface box connected via lead assembly is used, then motor control is enabled, but packaging and handling becomes more difficult
Solution Approach 1:
By integrating the user interface functionality directly into the motor connector, the patent eliminates the need for separate user interface boxes and lead assemblies. This consolidation reduces the number of discrete components that need to be packaged, handled, and assembled, thereby improving ease of manufacture and logistics while maintaining full motor control capability.
3Adaptability or versatility
If a separate user interface box and lead assembly are used, then motor adjustment functionality is provided, but assembly processes become more complex
Solution Approach 1:
The integration of user interface functionality into the motor connector eliminates the need for separate assembly steps involving user interface boxes and lead assemblies. The connector is designed as a single integrated component that can be directly installed at the motor location, simplifying the assembly process while providing complete motor adjustment capability.
4Adaptability or versatility
If a separate user interface box is used, then user access to control functions is provided, but motor envelope size increases
Solution Approach 1:
By consolidating the user interface functionality into the motor connector, the patent eliminates the need for separate external user interface boxes. The integrated controls are housed within or directly attached to the connector assembly, which occupies minimal space compared to a separate user interface box, thereby reducing the overall motor envelope while maintaining full user interface functionality.
Data Source
AI summary
A motor assembly includes a motor, a controller controlling at least one aspect of operation of the motor, and a control housing defining a control chamber. The controller is in part received within the control chamber. The controller includes a main electronics board and a modular connector assembly. The modular connector assembly includes a secondary electronics board and a connector at least in part supporting the secondary electronics board. The connector includes an inner connector portion and an outer connector portion. The connector extends through the control housing such that the inner connector portion is disposed inside the control chamber and the outer connector portion is disposed outside the control chamber. The outer connector portion defines a first access portal facilitating access to a first component of the secondary electronics board.