Electric Motor Plug Connection Layout for Tolerance-Safe Mounting
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Solution Overview
Problem
Existing electric motors in motor vehicles face challenges with high wear and complex mounting processes, particularly in auxiliary units, which can be exacerbated by environmental exposure and the need for precise electrical connections.
Innovation Solution
The electric motor is designed as a brushless direct current motor with a stator and rotor protected by a motor housing, featuring a switching unit and contact adapter with a plug connection that simplifies mounting by allowing electrical contact after the bearing plate is attached, reducing manufacturing costs and tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric motor uses a brushless direct current motor design with permanent magnets, then wear is reduced, but the manufacturing complexity and cost increase
Solution Approach 1:
The motor is divided into modular components (stator, rotor, switching unit, contact adapter) that can be manufactured separately and assembled, reducing overall manufacturing complexity while maintaining the brushless design benefits
Solution Approach 2:
The brushless design eliminates mechanical brushes and commutators, allowing the motor to operate without wear-prone sliding contacts, thus achieving self-maintenance through contactless electrical connection between stator and rotor
2Ease of manufacture
If the switching unit and contact adapter are integrated with the bearing plate, then mounting is simplified, but the precision of electrical connections becomes more difficult to ensure
Solution Approach 1:
The contact adapter serves as an intermediary component between the switching unit and the external electrical connection, providing a standardized interface that compensates for manufacturing tolerances and ensures reliable electrical contact without requiring high precision in the bearing plate assembly
Solution Approach 2:
The design allows for adjustment and compensation of electrical connection parameters through the contact adapter mechanism, enabling reliable connections despite variations in manufacturing tolerances of the bearing plate and other mounting 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
This design reduces wear, simplifies mounting, and enhances robustness by protecting electrical components, while allowing for precise electrical connections despite manufacturing tolerances, thus lowering production costs and increasing reliability.
Implementation Method 1
The electric motor has a rotor that includes several permanent magnets, and which is non-rotatably attached to a rotor shaft. The rotor shaft is rotatably mounted about a rotor axis via one or more bearings... The stator has several electrical coils which are electrically connected to three phases of a stator winding via a switching unit mounted on the stator
Data Source
AI summary
An electric motor of a motor vehicle, in particular an auxiliary unit, with a stator having a stator winding as well as with a rotor as well as with a switching unit and with a contact adapter for an electric motor connection. The stator and the rotor are arranged concentrically to a motor axis in a motor housing, which is closed with a bearing plate arranged perpendicular to the motor axis. The switching unit is placed on the stator and electrically contacted by the stator winding, and the contact adapter is connected to the switching unit and in electrical contact with it. A plug connection of the contact adapter is arranged in an opening of the bearing plate. A method for the mounting of an electric motor as well as an auxiliary unit of a motor vehicle are also provided.