Motor Plug-In Junction Box With Single-Level IP Sealing
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Solution Overview
Problem
Conventional motor connection devices face challenges in achieving flexible and cost-effective modular connections with IP protection, while maintaining reliable operation under severe environmental conditions, and often require multiple sealing and contact levels that complicate design and increase component count.
Innovation Solution
A plug-in junction box with a pot-like accommodation region and cylindrical screw bushings guides a contact carrier into a final assembly position, using guide elements and latching mechanisms for secure attachment, ensuring IP protection and reducing components through a modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a terminal box with multiple sealing and contact areas at different sealing levels is used, then connection functionality is achieved, but device complexity increases due to multiple components and sealing levels
Solution Approach 1:
The patent combines multiple sealing and contact areas into a single sealing level by integrating the contact carrier directly into the housing wall. This merging eliminates the need for separate terminal boxes and multiple sealing levels, reducing component count while maintaining connection functionality.
Solution Approach 2:
The housing wall serves multiple functions: it provides structural support, creates the sealing barrier, and integrates the contact carrier mounting. This multi-functionality reduces the need for separate dedicated terminal box components.
2Adaptability or versatility
If plug-in solutions are used for motor connection interfaces, then flexibility and modularity are improved, but achieving IP protection becomes more difficult
Solution Approach 1:
The contact carrier is merged with the housing structure at a single sealing level, eliminating gaps and interfaces that would compromise IP protection. The plug-in connector maintains modular flexibility while the integrated design ensures continuous sealing.
Solution Approach 2:
The sealing is concentrated at a single critical location where the contact carrier interfaces with the housing wall, allowing for optimized local sealing quality rather than distributing sealing requirements across multiple levels.
3Adaptability or versatility
If conventional terminal boxes with multiple sealing levels are used, then connection functionality is achieved, but manufacturing cost increases due to more components
Solution Approach 1:
By merging the contact carrier integration into the housing wall at a single sealing level, the patent reduces the total number of components that need to be manufactured, assembled, and sealed, thereby reducing manufacturing complexity and cost.
4Adaptability or versatility
If multiple sealing and contact areas at different sealing levels are present, then connection functionality is achieved, but the risk of errors increases due to more components
Solution Approach 1:
The patent merges multiple sealing and contact areas into a single integrated structure at one sealing level, reducing the number of potential failure points and error sources associated with multiple separate components and sealing interfaces.
Data Source
AI summary
An electronics unit and a plug-in junction box for plug-in connection of a plug-in connector integrated therein in the plug-in direction (S) into a plug-compatible socket of an electronics housing of an electronics unit of an electric motor. The junction box has a housing with a pot-like accommodation region delimited by housing walls for accommodating a contact carrier of the plug-in connector. A plurality of hollow-cylindrical screw bushings extending in the plug-in direction (S) are provided in the accommodation region. At a plurality of positions corresponding to those positions of the screw bushings, the contact carrier has externally located guide elements at which the contact carrier can be guided into its final assembly position, and in the final assembly position, the respective guide elements at least partially engage around the cylindrical screw bushings.