Motor Connector and PCB Layout for Visible Axial Assembly
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Solution Overview
Problem
The existing motor devices with deceleration mechanisms have a structure where the connector module is inserted from a side surface of the gear housing, making it difficult to visually observe the electrically connected portions, leading to degraded assembly performance.
Innovation Solution
The motor device is designed with a housing that stores the deceleration mechanism, featuring a connector storage unit and a substrate storage unit opened in a direction intersecting the axial direction of the rotation shaft, with conductive members extending in this direction for easy assembly and visual observation, using secured and movable jigs for precise positioning and insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the connector module is inserted from a side surface of the gear housing, then the motor device can be assembled in a compact space, but the electrically connected portion cannot be visually observed from the outside, leading to degraded assembly performance
Solution Approach 1:
The connector storage unit and substrate storage unit are opened in the axial direction of the rotation shaft rather than from the side surface, changing the assembly dimension from radial to axial. This allows visual observation of electrical connections from the end surface while maintaining compact overall dimensions through the flat-shaped housing design.
Solution Approach 2:
The housing serves as an intermediary structure that incorporates dedicated storage units for connectors and substrates. These storage units are opened in the axial direction to provide both visual access to electrical connections and structured guidance for assembly, mediating between the need for compact size and ease of assembly.
2Ease of manufacture
If the connector storage unit and substrate storage unit are opened in the axial direction, then visual observation of assembly state is enabled, but the housing structure becomes more complex
Solution Approach 1:
The housing performs multiple functions: it stores the deceleration mechanism, provides dedicated storage units for connectors and substrates with axial openings for visual observation, and guides the assembly process. By integrating these functions into a single structure, the apparent complexity is justified by the multi-functionality that simplifies overall assembly.
Solution Approach 2:
The housing is segmented into distinct storage units (connector storage unit and substrate storage unit) that are opened in the axial direction. This segmentation allows each unit to serve its specific function while maintaining visual observability, organizing the internal structure to balance complexity with assembly ease.
3Length of stationary object
If the motor device is formed into a flat shape with thin height dimension, then it can be placed in narrow space inside vehicle door, but the connector assembly becomes difficult to observe and assemble
Solution Approach 1:
While the housing height dimension is reduced for compact installation, the connector storage unit and substrate storage unit are opened in the axial direction (lengthwise), shifting the assembly access from the compressed radial dimension to the extended axial dimension. This allows maintainable assembly performance despite the flattened overall shape.
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
A connector storage unit 33d and a substrate storage unit 33c which are provided in a gear case 31 open in a direction (axial direction of output shaft) which intersects the axial direction of an armature shaft. As a result, when assembling a motor device 10, it is possible to store a connector member 60 and a control substrate 50 in the connector storage unit 33d and the substrate storage unit 33c, which have comparatively large openings, by insertion therein from the same direction. Consequently, it is possible to easily and definitively assemble the motor device 10 and to visually observe the state of assembly thereof from the outside.