Electric Motor Power Lead Stabilization

Solution Overview

Problem

Conventional connections for power leads in electric motors, such as weld and mechanical connections, fail due to vibrations and frequent movement, leading to electrical and mechanical disconnections that affect the motor's performance.

Innovation Solution

A separate mechanical connection using a wire connector to stabilize the power lead to a connection plate, combined with a resilient electrical connection, such as a weld, to ensure the stability of the power leads' attachment to the motor terminals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single connection point is used for both electrical and mechanical connection, then the device complexity is reduced, but the reliability of the connection deteriorates under vibration and movement

Engineering Contradiction:

Improveconnection structureVSAvoidconnection stability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The connection structure is divided into two separate functions: a first connection point for electrical connection and a second connection point for mechanical connection. This segmentation allows each connection point to be optimized for its specific function, preventing the electrical connection from being subjected to mechanical stresses and vibrations that would otherwise cause failure.

Inventive Principle:

Principle #1Segmentation

2Productivity

If weld connection is used, then the manufacturing speed and cost are improved, but the connection reliability deteriorates under vibration

Engineering Contradiction:

Improvemanufacturing speedVSAvoidconnection stability under vibration

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The connection structure is divided into two separate functions: a first connection point for electrical connection and a second connection point for mechanical connection. This segmentation allows each connection point to be optimized for its specific function, preventing the electrical connection from being subjected to mechanical stresses and vibrations that would otherwise cause failure.

Inventive Principle:

Principle #1Segmentation

3Strength

If mechanical connection using wire connector is used, then the mechanical connection strength is improved, but the electrical connection reliability deteriorates due to micro-arcing and erosion

Engineering Contradiction:

Improvemechanical connection strengthVSAvoidelectrical connection stability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The connection structure is divided into two separate functions: a first connection point for electrical connection and a second connection point for mechanical connection. This segmentation allows each connection point to be optimized for its specific function, preventing the electrical connection from being subjected to mechanical stresses and vibrations that would otherwise cause failure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal acts as an intermediary element that receives both the electrical connection (via the first connection point) and the mechanical connection (via the second connection point). This intermediary structure allows the mechanical strength to be provided by the second connection point while the electrical connection stability is maintained by the first connection point, preventing micro-arcing and erosion at the electrical interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration significantly improves the stability of the connections between power leads and motor terminals, preventing electrical erosion and mechanical disconnection, thus ensuring reliable motor operation under vibrations and frequent movement.

Implementation Method 1

the power lead is mechanically connected to the connection plate by a wire connector

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Implementation Method 2

the power lead is electrically connected to the connection plate by weld connection

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 3

the electrical connection is subject to deterioration as the vibrations cause micro-arcing between the connector and the terminal leading to electrical erosion

Methodology Applied

Scientific EffectVibration Isolation: Vibration

Data Source

PatentUS10128715B2Electric motor with reliable wire connection

Publication Date: 2018.11.13 JOHNSON ELECTRIC INTERNATIONAL AG

AI summary

An electric motor has a stator, a rotor rotatable with respect to the stator, motor windings, a connection plate electrically connected to the motor windings, and a power lead for connecting the motor to a power source. The power lead is connected to the connection plate by an electrical connection and by a separate mechanical connection. The mechanical connection protects the electrical connection from vibration or movement which may otherwise break the electrical connection.