Motor Housing Crimped Tab Connection for Vibration Resistance
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Solution Overview
Problem
Existing motor housing designs for electric motors in motor vehicle technology face challenges in achieving precise coaxial alignment and mechanical stability, particularly under vibration, temperature fluctuations, and contamination, with conventional connection methods like screws leading to play and potential failure, while alternative methods like gluing or welding are impractical for mass production.
Innovation Solution
The motor housing features radially projecting tabs on the housing cover module that engage with slots on the housing shell, allowing for precise alignment and secure fixation through crimping deformation elements, eliminating the need for additional fasteners and enabling automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If screws are used to connect housing shell to housing cover assembly, then the connection can be easily assembled and disassembled, but the connection elements tend to loosen under vibration and create play
Solution Approach 1:
The connection system is segmented into multiple independent connection elements distributed around the circumference, each providing localized stabilization. The housing cover assembly is divided into a body and radially extending tabs that engage with corresponding slots in the housing shell, creating distributed connection points that resist vibrational loosening.
Solution Approach 2:
The tabs are pre-formed with deformation elements that are crimped during assembly to create permanent form-locking engagement with the housing shell slots. This preliminary deformation action ensures that the connection elements are pre-loaded and pre-positioned to resist subsequent vibrational forces, preventing loosening before operation begins.
2Ease of manufacture
If conventional connection methods are used, then assembly can be performed with simple equipment, but manufacturing precision and coaxiality are difficult to achieve
Solution Approach 1:
The tabs are pre-formed on the housing cover assembly with specific geometries and deformation elements that guide their engagement into the housing shell slots. This preliminary formation ensures that when assembled, the tabs naturally align and engage at precise positions, achieving high coaxiality without requiring complex alignment equipment or procedures.
Solution Approach 2:
The deformation elements on the tabs are designed to self-align and self-center during the crimping process. As the tabs are crimped into the slots, the deformation automatically positions them concentrically with the housing shell, eliminating the need for external alignment tools or complex manufacturing equipment to achieve precise coaxiality.
3Strength
If additional fasteners are used to secure housing components, then connection strength is improved, but device complexity increases
Solution Approach 1:
The connection function is merged into the housing cover assembly itself through the integration of tabs with deformation elements. Rather than using separate fasteners, the tabs are formed as integral parts of the housing cover assembly, combining the structural component with the fastening function. This eliminates additional fastener components while maintaining strong form-locking connections.
Solution Approach 2:
The tabs serve multiple functions: they provide structural support as part of the housing cover assembly, act as positioning elements for alignment, and function as fasteners through their deformation engagement with the housing shell slots. This multi-functionality eliminates the need for separate dedicated fasteners, reducing component count while maintaining connection strength.
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
This solution ensures precise, play-free, and stable connection of the housing components, capable of transmitting forces and torques, while minimizing vibration-induced noise and facilitating cost-effective, high-quality automated manufacturing.
Implementation Method 1
plastic deformation, by axial application of force, using an axially engaging tool, in a crimping manner well-known in similar contexts
Data Source
AI summary
A motor housing for an electric motor has a generally cylindrical housing shell (10), which, at one end (26), accommodates a first bearing and a housing cover module (12) such that the housing cover module (12) closes an opposing, open end of the housing shell (10), and serves as a second bearing. The cover module (12) is preferably of metal material and is integrally formed with a plurality of projecting tab and/or arm portions (14, 16, 18). Around the housing shell (10), several recesses or slots (20) are formed, flanked by deformable elements (30,32). By axially applying a tool (60), the deformable elements are deformed to secure the tabs (14, 16, 18) within the slots (20) and to thereby connect the shell (10) and the cover module (12) axially together. The resulting structure is highly resistant to vibrational decoupling, and can readily be obtained by high-speed automated production steps.