Motor Programming Tool Handle-Mounted PCB

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Solution Overview

Problem

Conventional motor programming tools require significant insertion and separation forces, leading to component damage and downtime due to repeated plugging and unplugging, which is time-consuming and reduces the tool's useful life.

Innovation Solution

A motor programming tool with a tool body and terminal connecting assemblies that directly contact motor terminals, providing a low-impact association and secure electrical connection, along with circuitry for automatic signal transmission and power supply, eliminating the need for high insertion and separation forces and allowing easy replacement of terminal elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional motor programming tools use mating terminals and sockets for connection, then electrical connection can be established, but significant insertion and separation forces are required leading to component damage and reduced tool life

Engineering Contradiction:

Improvecomponent durabilityVSAvoidinsertion and separation force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The patent replaces the traditional mechanical mating terminal and socket system with a different connection mechanism that eliminates the need for high insertion and separation forces. The new system uses an alternative mechanical interface that achieves secure electrical connection without the damaging force requirements of conventional plugging and unplugging operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the mechanical parameters of the connection system by modifying how the programming tool interfaces with the motor terminals. Instead of using deep-insertion sockets that require significant force, the new design uses a connection mechanism with different geometric and force characteristics that reduces wear and extends component life.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If repeated plugging and unplugging operations are performed with conventional tools, then programming can be completed, but component damage occurs rendering terminals or sockets unusable

Engineering Contradiction:

Improveprogramming speedVSAvoidcomponent usability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces the damaging mechanical connection system with a new interface that allows repeated connection and disconnection operations without component damage. This substitution maintains programming productivity while eliminating the reliability issues associated with conventional mating terminals and sockets.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of repair

If damaged sockets in conventional programming tools are replaced, then tool functionality is restored, but significant downtime occurs due to permanent wiring reconstruction

Engineering Contradiction:

Improvesocket replacement simplicityVSAvoidtool downtime

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The patent divides the connection system into separable modules, allowing the programming tool interface to be independently replaced without affecting the permanent wiring. This segmentation enables quick swap of the connection component while leaving the wired circuitry intact, dramatically reducing repair time.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces an intermediary connection component that sits between the programming tool and the motor terminals. This intermediary can be easily replaced without disturbing the permanent wiring, serving as a disposable or easily swapable interface that simplifies maintenance.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If conventional programming tools are designed with permanently connected wiring to sockets, then electrical connection is stable, but repair requires reconstruction of permanent wiring connections

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidwiring reconnection complexity

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent segments the electrical connection system into a permanent wired portion and a replaceable interface portion. This allows the stable permanent wiring to remain intact while the interface component is easily replaced, combining connection stability with repair simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces an intermediary component that separates the permanent wiring from the connection interface. This intermediary absorbs the wear and tear of repeated connections, protecting the permanent wiring while allowing easy replacement of the interface portion.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8837104B2Motor programming tool with handle-mounted PCB

Publication Date: 2014.09.16 NIDEC MOTOR CORP

AI summary

A motor programming tool is disclosed for associating with a connection block of a motor and sending signals to a programmable controller of the motor, where the connection block includes a plurality of terminals coupled to the controller. The programming tool includes a tool body with an interface generally corresponding with the connection block of the motor, wiring operable to carry the signals, and a plurality of terminal connecting assemblies to associate with the motor terminals. The programming tool includes circuitry disposed in the tool body. The circuitry is electrically connected to the wiring and includes a power transmission portion and a data transmission portion.