Motor Connector Integrating Phase Terminals to Eliminate Fusing Bonding
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Solution Overview
Problem
Conventional methods for connecting three-phase coil connecting portions and power terminals in drive motors for environmentally-friendly vehicles are inconvenient, requiring separate connection terminals, pressing, fusing bonding, and expensive equipment, as well as additional insulating processing.
Innovation Solution
A connector system comprising an under terminal block and an upper terminal block made of insulating material, with a receiving groove, drawn-out groove, and engagement bolts, that electrically connects three-phase coil connecting portions and power terminals without the need for separate connection terminals or pressing/fusing bonding, reducing costs and cycle time while improving insulating reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pressing and fusing bonding method is used to connect phase terminal with coil connecting portion, then electrical connection is achieved, but the process becomes complex requiring expensive equipment and additional insulating processing
Solution Approach 1:
The patent combines the phase terminal and connector body into a single integrated component. The phase terminal is directly formed as part of the connector housing, eliminating the need for separate pressing and fusing bonding operations. This merging of components simplifies the connection process while maintaining reliable electrical connection between the coil and power supply.
2Reliability
If separate connection terminal with pressing and fusing bonding is used, then electrical connection is established, but work number increases and expensive equipment is required
Solution Approach 1:
The connector integrates the phase terminal directly into the connector body, eliminating separate assembly steps. The coil connecting portion is directly inserted into the integrated phase terminal structure, reducing the number of operations required and eliminating the need for expensive fusing bonding equipment while maintaining connection reliability.
3Reliability
If conventional connection method with separate phase terminal is used, then connection is achieved, but separate insulating processing is required for each connected portion
Solution Approach 1:
The phase terminal is integrated into the connector body as a unified structure. This merging eliminates the need for separate insulating processing of individual connection points, as the integrated design provides inherent insulation through the connector housing material and structure.
4Reliability
If phase terminal is pressed and fusing bonded to coil connecting portion, then electrical connection is established, but the process is inconvenient and requires multiple steps
Solution Approach 1:
The connector body and phase terminal are formed as an integrated structure, allowing the coil connecting portion to be directly inserted and connected without requiring pressing or fusing bonding operations. This simplifies the connection process to a single insertion step, greatly improving ease of operation while maintaining reliable electrical connection.
Data Source
AI summary
A connector for connecting a motor is provided. The connector for connecting a motor for electrically connecting a three phase coil connecting portion that is drawn out from a motor and a three phase power terminal that is connected with a power cable includes: i) a under terminal block that houses the each power terminal and the each coil connecting portion; ii) an upper terminal block that is coupled to the under terminal block and that presses the each power terminal and the each coil connecting portion; and iii) an engagement portion that engages the under terminal block and the upper terminal block.