Integrated Motor Electrical Connection Reducing Assembly Complexity
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Solution Overview
Problem
Existing electrical connection arrangements for motors are complex, requiring many individual parts, leading to high assembly and testing costs, and are not easily adaptable to motor applications due to installation space and tolerance issues.
Innovation Solution
A compact, preassembled electrical connection arrangement featuring a one-piece rigid conductor rail with integrated terminals, overmoulded with insulating material, reducing assembly effort and susceptibility to errors, and allowing for easy adaptation to motor applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If commercially available connectors and cable harnesses are used, then electrical connections can be established, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple separate components (connectors, cable harness, protection elements) into a single integrated connector housing that contains all electrical connections and protective structures. This merging eliminates the need for separate assembly steps and reduces the total number of parts while maintaining reliable electrical connections.
2Reliability
If commercially available connectors with crimp contacts are used, then electrical connections can be made, but additional testing and quality control are required
Solution Approach 1:
The connector housing integrates the electrical connections directly into the molded structure, eliminating the need for separate crimping operations that require quality testing. The insulation and connection structures are formed in a single manufacturing process, making the product self-sufficient and eliminating additional testing steps.
3Ease of operation
If ready-made assembly groups are used, then assembly effort is reduced, but the structure becomes complex and difficult to adapt to motor applications
Solution Approach 1:
The connector housing is designed with universal features that allow it to serve multiple functions: electrical connection, mechanical protection, insulation, and adaptation to motor applications. The integrated design with standardized mounting features and flexible internal configuration enables it to be universally applied to various motor types while requiring minimal assembly effort.
4Volume of moving object
If rigid electrical connecting lines are used, then installation space is reduced, but insulation and protection against environmental influences must be added
Solution Approach 1:
The patent merges the rigid electrical connecting lines with insulation material and protective structures into a single integrated connector housing. This combination provides compact installation space while simultaneously offering protection against environmental influences such as moisture and contamination, eliminating the need for separate protective components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces assembly complexity and costs while ensuring reliable electrical insulation and protection against environmental influences, enabling efficient and cost-effective motor connections with minimal parts.
Implementation Method 1
the conductor rail and at least parts of the connection devices being surrounded together with an insulating material and being insulated from one another
Data Source
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AI summary
The invention relates to an electrical connection arrangement (1) for a motor and to the method for production thereof, comprising a first electrical terminal device (10) arranged at the end having electrical terminals (11), a second electrical terminal device (20) arranged at the ends having electrical terminals (21), and a line rail (30) which is formed integrally with the terminals and connects to the two terminal devices, wherein the line rail and at least parts of the terminal devices are jointly surrounded and insulated relative to one another by an insulating material.