Electric Motor Contact Grid Segmentation
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Solution Overview
Problem
Existing electric motor manufacturing processes for hand tools are complex and inefficient, particularly in handling and insulating multiple contacts within stamped grids, leading to increased production and assembly costs and potential errors.
Innovation Solution
A simplified electric motor design featuring a contact grid with lugs for alignment and positioning, where excitation windings are wound continuously and separated to connect directly with conductor tracks, reducing the need for complex intermediate steps and allowing for high mechanical stability and reduced ohmic losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a stamped grid with multiple contacts is used to interconnect windings, then the motor can achieve compact construction, but the production and handling becomes particularly complex due to the need to separate contact areas for insulation
Solution Approach 1:
The contact grid is divided into multiple separate contact elements instead of a single integrated stamped grid. Each contact element can be independently handled and positioned, eliminating the need for complex separation of contact areas during production while maintaining compact motor construction.
Solution Approach 2:
An insulating body is introduced as an intermediary component that holds the separate contact elements. This mediator provides the necessary insulation between contact areas without requiring complex separation processes, simplifying production while achieving compact design.
2Reliability
If contact areas are completely separated for insulation in stamped grids, then reliable insulation is achieved, but production and handling complexity increases significantly
Solution Approach 1:
The insulating body serves as a mediator that provides reliable insulation between contact areas without requiring the contact areas themselves to be completely separated. The contacts are mounted on the insulating body, which naturally provides electrical isolation, thereby maintaining insulation reliability while significantly easing production and handling.
Solution Approach 2:
The insulating function and the mounting function are merged into a single insulating body component. This integration eliminates the need for separate insulation measures and complex separation processes, making production easier while ensuring reliable insulation.
3Adaptability or versatility
If multiple different contacts are implemented in one lattice layer, then contact functionality is increased, but the lattice layers become particularly complex to produce and handle
Solution Approach 1:
Different contact types are implemented on separate contact elements rather than integrating them into a single complex lattice layer. Each contact element can be optimized for its specific function and can be independently manufactured and positioned on the insulating body, maintaining versatility while reducing complexity.
Solution Approach 2:
The insulating body serves as a universal platform that can accommodate multiple different types of contacts. This multi-functional base structure allows various contact elements to be mounted in a standardized manner, increasing contact functionality without proportionally increasing overall complexity.
4Reliability
If winding wire is fixed to contacts on the contact grid, then reliable contacting is achieved, but additional fixing and securing steps are required in assembly
Solution Approach 1:
The contacting function and the fixing function are merged into a single operation. The winding wire is fixed directly to the contacts on the contact grid in one step, eliminating the need for separate fixing and securing steps. This integration maintains reliable contacting while significantly improving assembly productivity.
Data Source
Figure 1~3
Figure 4~7
Figure 8~10
AI summary
The motor (16) i.e. electronically commutated electric motor, has a stator with excitation windings wound partially from a winding wire. A contact grid contacts the windings and comprises conductor tracks. The tracks comprise contacts (20, 22, 24) for fixing the winding wire. A motor controller (18) is coupled with the windings via the grid for powering the windings to generate a rotating electric field. The winding wire is connected between the contacts for electrically connecting the windings for generating the rotating electric field when powered by the controller. An independent claim is also included for a method for manufacturing an electric motor.