Electric Motor Plug Adapter Alignment for Simpler Assembly
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Solution Overview
Problem
Existing electric motor assembly processes for motor vehicles often result in increased waste and complexity, particularly in the connection of electrical coils and the alignment of components within the motor housing.
Innovation Solution
The electric motor design incorporates a switching unit with separate busbars for connecting electrical coils, and a contact adapter with a plug connection that is mounted in a floating manner, allowing for precise alignment and reduced manufacturing tolerances, thereby simplifying assembly and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional assembly processes are used for electric motors, then manufacturing experience shows increased waste and complexity, but the patent introduces a novel assembly method with switching unit and contact adapter to reduce waste and simplify assembly
Solution Approach 1:
The patent divides the electrical connection system into separate functional components: a switching unit with busbars for coil connections and a contact adapter with plug connections for external wiring. This segmentation allows each component to be manufactured and assembled independently, reducing waste from defective integrated assemblies and simplifying the overall manufacturing process.
Solution Approach 2:
The switching unit is pre-assembled and electrically connected to the stator winding before final motor assembly. The contact adapter is also prepared in advance with its plug connections. This preliminary preparation reduces assembly complexity and waste during final motor assembly, as components are ready for direct installation without complex field modifications.
2Manufacturing precision
If precise alignment is required for electrical connections, then manufacturing tolerances must be tight, but the patent uses a floating mounting method for the contact adapter to simplify alignment
Solution Approach 1:
The contact adapter is mounted in a floating manner on the switching unit, allowing it to move and self-align during assembly. This dynamic mounting approach eliminates the need for tight manufacturing tolerances and complex alignment procedures, while still achieving precise electrical connections through the floating adjustment capability.
3Productivity
If electrical coils are connected using traditional methods, then the assembly process becomes complex and waste increases, but the patent uses separate busbars in the switching unit to simplify connections
Solution Approach 1:
The patent combines multiple electrical connection functions into a single integrated switching unit structure. The busbars are formed as one piece or pre-assembled unit that simultaneously connects multiple stator windings, eliminating the need for separate connection operations and reducing material waste from multiple separate connectors and wiring operations.
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 design enhances the efficiency of the electric motor assembly process by reducing waste and simplifying the assembly of electrical connections, while also improving the robustness and reliability of the motor components.
Implementation Method 1
The electric motor has a rotor containing multiple permanent magnets that are non-rotatably attached to a rotor shaft. The rotor shaft is mounted to rotate about a rotor axis by one or more bearings... The stator has multiple electrical coils that are electrically connected to three phases of a stator winding by means of a switching unit
Data Source
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Figure 3
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AI summary
The invention relates to an electric motor (32) of a motor vehicle (2), in particular an auxiliary assembly (16), comprising a stator (34), which has a stator winding (46), as well as a rotor (36), a switch unit (38), and a contact adapter (40) for an electric motor connection. The stator (34) and the rotor (36) are arranged in a motor housing (52) concentrically to a motor axis (44), said motor housing being closed by a bearing shield (54) arranged perpendicularly to the motor axis (44). The switch unit (38) is positioned on the stator (34) and electrically contacts the stator winding (46), and the contact adapter (40) is attached to the switch unit (38) and electrically contacts same. A plug connection (62) of the contact adapter (40) is arranged in an opening (68) of the bearing shield (54). The invention additionally relates to a method (40) for installing an electric motor (32) and to an auxiliary assembly (16) of a motor vehicle (2).