C-Shaped Motor Connection Ring Terminal for Accurate Resistance Welding

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Solution Overview

Problem

Existing connection ring terminals in motors often deviate from their predetermined position after welding, leading to positional inaccuracies and increased costs due to high-cost laser welding. Additionally, the connection between the connection ring terminal and the connection ring is prone to detachment under radial forces.

Innovation Solution

A connection ring terminal with a C-shaped connection part that surrounds the lead-out end in the circumferential direction, allowing for precise positioning in radial, circumferential, and axial directions. This design enables simple and cost-effective resistance welding and enhances the structural integrity of the connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser welding is used to connect the connection ring terminal to the connection ring, then the welding speed and automation are improved, but the manufacturing cost increases significantly

Engineering Contradiction:

Improvewelding speedVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive laser welding with cost-effective resistance welding, using affordable welding tools and processes while maintaining connection quality. This substitutes high-cost equipment with lower-cost alternatives that achieve the same functional outcome.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces the thermal field-based laser welding with a mechanical field-based resistance welding process, utilizing electrical resistance and mechanical pressure instead of high-energy laser beams, thereby reducing equipment costs and manufacturing complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If additional tooling is used to position the connection ring terminal during welding, then the positioning accuracy is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvepositioning accuracyVSAvoidtooling complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The connection ring terminal's own structure provides positioning functionality through its connection part geometry, eliminating the need for external positioning tooling. The terminal positions itself relative to the connection ring through its designed shape, achieving self-positioning during the welding process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The connection part of the terminal serves multiple functions: it provides both the welding surface and the positioning reference. This multi-functional design integrates positioning and connection functions into a single structural element, reducing the need for separate positioning mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If the connection ring terminal is connected only at a single welding point, then the manufacturing process is simplified, but the connection reliability decreases under radial forces

Engineering Contradiction:

Improvewelding process simplicityVSAvoidconnection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The connection part is divided into multiple welding points distributed around the connection ring, transforming a single-point connection into a multi-point connection system. This segmentation distributes mechanical stresses and improves overall connection reliability while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple welding points are combined to form an integrated connection system where the connection part welds to multiple locations on the connection ring simultaneously or sequentially, creating a robust multi-point attachment that resists radial forces more effectively than a single weld point.

Inventive Principle:

Principle #5Merging (Combining)

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

The solution provides high positional accuracy, reduces manufacturing costs, and enhances the reliability of the connection ring terminal by preventing detachment, thus improving the overall performance and durability of the motor.

Implementation Method 1

the connection part is used for surrounding the lead-out end at least in a circumferential direction of the lead-out end

Methodology Applied

Scientific EffectGeometric constraint: Geometry

Implementation Method 2

The welding is, for example, laser welding

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 3

The connection ring terminal and the connection ring 20 are connected through a welding process

Methodology Applied

Scientific EffectResistance welding: Welding

Data Source

PatentUS12341392B2Connection ring terminal, connection ring, and motor

Publication Date: 2025.06.24 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A connection ring terminal. The connection ring terminal is used for connecting to a lead-out end of a connection ring of a motor; and the connection ring terminal comprises a main body and a connection part located at one end of the main body, wherein the connection part is used for surrounding the lead-out end at least in the circumferential direction of the lead-out end, such that the connection ring terminal can be positioned relative to the lead-out end in the radial and circumferential directions of the connection ring. A connection ring and a motor is also provided.