Electric Motor Connector Assembly for Cable-Free Stator Mounting
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Solution Overview
Problem
The manufacturing process of electric motors with connectors for power and communication signals is complex and lacks automation, leading to inefficiencies and potential disconnection risks.
Innovation Solution
A wiring structure with multiple connectors is introduced, allowing for the connection of electronic components to the stator and substrate through a series of connectors that can be easily attached and detached, facilitating the manufacturing process and reducing the risk of disconnection by eliminating cable lines, thereby improving reliability and noise resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional cable lines are used to connect connectors, then flexibility and ease of connection are improved, but the risk of disconnection increases and manufacturing complexity increases
Solution Approach 1:
The patent removes cable lines from the connector connection system entirely. The connectors are designed to establish direct electrical contact through rigid structural elements (such as contact pins and contact holes) without requiring flexible cable intermediaries. This extraction of the cable component eliminates the disconnection risks associated with cable fatigue and improper handling while maintaining reliable electrical connectivity.
Solution Approach 2:
The patent integrates the connection function directly into the structural components of the electric motor assembly. The connectors are merged with the housing and stator structures, creating a unified assembly where the connection elements are built-in rather than separate attachable components. This merging eliminates the need for separate cable management and connection procedures, reducing both manufacturing steps and potential failure points.
2Reliability
If multiple separate connection steps are used to attach substrate to stator, then connection reliability is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent combines the substrate attachment process with the connector connection process into a single integrated operation. When the substrate is positioned and attached to the stator, the connectors automatically engage with each other through predefined alignment features (such as guide pins and matching contact geometries). This merging of operations eliminates the need for separate connection steps while ensuring reliable electrical contact through the integrated design.
Solution Approach 2:
The connector design incorporates self-alignment and self-engagement features that automatically ensure proper connection during the substrate attachment process. The structural elements guide the connectors into correct positioning and establish electrical contact without requiring additional manual intervention or complex alignment procedures. This self-service mechanism simplifies manufacturing while maintaining connection reliability.
3Adaptability or versatility
If cable lines are used for signal transmission, then flexibility in routing is improved, but noise resistance and communication speed are reduced
Solution Approach 1:
The patent removes cable lines from the signal transmission path and replaces them with direct rigid electrical contacts between connectors. This extraction eliminates the cable medium that is susceptible to electromagnetic interference and signal degradation. The direct contact approach provides superior noise resistance and faster signal transmission while the routing flexibility is maintained through the design of the connector positions and structural layout within the motor assembly.
Data Source
AI summary
An electric motor that can facilitate a process of manufacturing the electric motor. The electric motor includes a substrate mounted with an electronic component, a first connector provided on a stator, the first connector configured to receive a power signal input to a coil and a communication signal with the electronic component, and a wiring structure communicably connecting the electronic component and the first connector. The wiring structure has a second connector mounted on the substrate, and a third connector fixed to the stator, the third connector configured to be connected to the second connector and configured to attach the substrate to the stator by an operation of moving the substrate toward the stator.