Motor End Cover Assembly for Compact Lead Wire Routing
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Solution Overview
Problem
In compact power tools with limited space, electric motors face challenges in achieving a compact design while maintaining strong power output due to the radial dimensions of motor lead wires at the lead-out position.
Innovation Solution
The electric motor design includes an end cover assembly with coil end covers and a fixing member that allows for changing the lead-out direction of motor lead wires at least twice, reducing the radial dimension and enhancing compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electric motor is designed with conventional lead wire routing, then the motor can be manufactured with standard structure, but the radial dimension of motor lead wires increases, reducing compactness
Solution Approach 1:
The patent applies dimensionality change by routing motor lead wires through the axial direction (length dimension) of the end cover assembly rather than allowing them to extend radially. The lead wires pass through openings in the coil end cover and are secured by a fixing member, effectively transforming the spatial arrangement from radial extension to axial routing, thereby reducing the radial dimension of the motor while maintaining electrical connectivity.
2Power
If the electric motor is designed to output strong power, then the power output increases, but the dimension of the electric motor increases beyond preset range
Solution Approach 1:
The patent reduces the overall motor dimension by changing the spatial arrangement of lead wires from radial to axial routing. This allows the motor to maintain strong power output while reducing the radial dimension, enabling the motor to fit within preset size ranges required for compact power tools.
3Volume of moving object
If the electric motor is designed with compact structure, then the motor dimension is reduced, but the lead wire routing becomes more complex
Solution Approach 1:
The patent merges the lead wire routing function with the existing end cover assembly structure. The coil end cover and fixing member, which are already part of the motor's end cover assembly, are utilized to route and secure the lead wires axially. This integration avoids adding separate complex routing mechanisms while achieving compact motor dimensions.
4Ease of operation
If the motor lead wires are routed radially, then the connection to external components is simplified, but the radial dimension of the motor increases
Solution Approach 1:
The patent changes the lead wire routing from radial to axial direction. The lead wires pass through openings in the coil end cover axially and are secured by a fixing member, allowing connection to external components while maintaining reduced radial dimension. This axial routing through the end cover assembly provides both compactness and accessible connection points.
Data Source
AI summary
A power tool includes a working assembly and an electric motor. The electric motor is used for driving the working assembly to work. The electric motor includes a rotor assembly, a stator assembly, and an end cover assembly. The end cover assembly is used for fixing windings and leading out multiple motor lead wires. The end cover assembly includes coil end covers and a fixing member. The coil end cover is at least partially embedded into the stator assembly. The fixing member mates with the coil end cover to fix the motor lead wires. The end cover assembly is capable of changing the lead-out direction of the motor lead wires at least twice.