Temperature Sensor Assembly in Drive Motor Terminal Holder
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Solution Overview
Problem
The existing methods for assembling temperature sensors in drive motors are inefficient, increasing assembly processes and costs, and expose the sensor unit to external damage due to narrow contact surfaces and the use of adhesives, which degrades sensing performance and raises material and facility costs.
Innovation Solution
A structure and method for assembling a temperature sensor using an annular terminal unit with a terminal holder, cores, bobbins, and a stator coil, where the temperature sensor is inserted vertically between the bobbins and fixed using an elastic groove and separation-preventing protrusions, reducing direct contact risks and eliminating the need for additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature sensor is installed on the stator coil using a jig and adhesive, then the temperature sensor can be fixed to measure stator coil temperature, but the number and time of assembly processes increase and costs increase
Solution Approach 1:
The temperature sensor is integrated into the terminal holder structure, merging two separate components (temperature sensor and terminal holder) into a single unified assembly. This eliminates the need for separate assembly processes and adhesive materials, reducing both assembly complexity and costs while maintaining reliable temperature measurement functionality.
Solution Approach 2:
The terminal holder is designed to serve multiple functions: it provides electrical terminals and simultaneously houses the temperature sensor. This multi-functional design eliminates the need for separate mounting structures and adhesive fixation processes, simplifying the overall assembly while ensuring reliable temperature sensing.
2Reliability
If the temperature sensor is installed on the stator coil using adhesive, then the temperature sensor can be fixed, but the sensor unit may be exposed to external factors and damaged
Solution Approach 1:
The terminal holder structure provides pre-established protection for the temperature sensor by enclosing it within its structure. This beforehand cushioning prevents the sensor from being exposed to external harmful factors such as moisture, dust, and physical damage, while maintaining secure fixation without requiring adhesive.
3Ease of operation
If the temperature sensor contacts one side surface of the stator coil, then the temperature sensor can be positioned, but the contact surface is narrow and sensing performance is degraded
Solution Approach 1:
Instead of relying on narrow surface contact between the temperature sensor and stator coil, the design transitions to a three-dimensional integration where the temperature sensor is housed within the terminal holder structure. This dimensional change allows for better thermal coupling and more comprehensive temperature sensing without compromising positioning ease.
4Reliability
If adhesive members such as jig epoxy are used to fix the temperature sensor, then the temperature sensor can be secured, but material costs and assembly facility costs increase
Solution Approach 1:
The design extracts and eliminates the adhesive material (jig epoxy) from the assembly process by integrating the temperature sensor directly into the terminal holder structure. This removal of unnecessary components reduces both material costs and the complexity of assembly facilities required, while maintaining secure and reliable sensor fixation.
Data Source
AI summary
A structure for assembling a temperature sensor of an annular terminal unit for a drive motor. The structure includes a terminal holder having an annular shape, a temperature sensor fixed to the terminal holder, a plurality of cores radially arranged on a lower surface of the terminal holder, a bobbin inserted into each of the plurality of cores, and a stator coil wound around each of the bobbins. The temperature sensor passes through the terminal holder in a vertical direction of the terminal holder and is inserted between the bobbins around which the stator coils are wound.