Motor Starter Connecting Packages with Top-Down Robotic Assembly
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Solution Overview
Problem
Conventional motor starter connecting packages face increased assembly costs due to manual assembly requirements and quality control challenges, particularly with components like PTC elements that require individual testing, which can lead to disruption during enclosure and prolonged testing times.
Innovation Solution
A device design enabling top-down assembly of circuit components, allowing robotic placement and securing without a circuit board or potting material, with a universal base and cover configuration that securely connects the motor starter circuit, facilitating quick testing after enclosure and eliminating the need for filler material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional motor starter connecting packages are manufactured with manual assembly requirements, then assembly precision can be maintained, but assembly cost increases significantly
Solution Approach 1:
The motor starter is divided into modular components including a base, cover, terminal assembly, and circuit elements that can be independently manufactured and then automatically assembled. The base and cover are separate components that enclose the circuit elements, allowing each part to be optimized for automated manufacturing while maintaining overall assembly precision
Solution Approach 2:
The base and cover are designed with universal features that accommodate various terminal configurations and circuit element arrangements. The base includes standardized mounting structures and the cover includes corresponding receptacles, enabling a single automated assembly system to handle multiple product variants without manual intervention
2Loss of time
If circuit elements are tested individually before enclosing, then testing time is reduced, but the circuit elements may be disrupted during the enclosing process
Solution Approach 1:
Circuit elements are tested individually before being enclosed in the base and cover assembly. The base is designed with dedicated test access features including test terminals and openings that allow electrical testing to be performed on the circuit elements while they are still accessible, enabling quality control before final enclosure
Solution Approach 2:
The base and cover structure serves as an intermediary that provides both mechanical support and test access. The base includes openings and the cover includes receptacles that allow test probes to reach the circuit elements even after enclosure, acting as a mediator between the need for protection and the need for accessible testing
3Productivity
If testing is performed after enclosing circuit elements, then assembly time is reduced, but testing time increases due to heating requirements
Solution Approach 1:
Electrical testing of circuit elements is performed before the cover is finalized, when test access is still available through the base openings and cover receptacles. This preliminary testing captures quality issues early in the assembly process before the product is fully enclosed and shipped
Solution Approach 2:
The testing process is segmented into individual circuit element tests performed before enclosure, rather than a single comprehensive test after enclosure. The base and cover design facilitates this segmented approach by providing accessible test points throughout the assembly process
4Stability of the object's composition
If potting material or filler material is used to secure circuit elements, then mechanical stability is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent eliminates potting material and filler material from the assembly, extracting the unnecessary complexity of handling and applying these materials. Instead, circuit elements are mechanically secured through the base and cover structures alone, simplifying the assembly process while maintaining stability
Solution Approach 2:
The base and cover structures are designed to self-secure the circuit elements through their geometric features including recesses, protrusions, and snap-fit connections. The assembly is self-sufficient and does not require additional potting or filling materials to achieve mechanical stability
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 approach reduces assembly time and costs by enabling increased automation, ensuring secure connection of motor starter circuits without manual assembly, and allowing for efficient testing post-enclosure, thus minimizing defects and testing delays.
Implementation Method 1
The base includes a first electric motor starter circuit support structure, and is configured to receive the circuit elements in a z-axis direction for assembling the electric motor starter circuit on the base
Implementation Method 2
The cover is also configured to couple to the base such that when the cover and base are coupled together, they form an enclosure of the electric motor starter circuit in which the electric motor starter circuit is firmly secured between the first electric motor starter circuit support structure and the second electric motor starter circuit support structure by action of opposing force
Data Source
AI summary
Techniques disclosed herein include systems and methods for assembly of electric motor starter connecting packages that enable increased automation and reduced assembly via top-down assembly of circuit components, thereby allowing robotic placement, connection, and securing of circuit components. The connecting package can include an electric motor starter, with optional overload protector, packaged as one unit. The motor starter can include an electrical circuit containing a triac, current transformer, Positive Temperature Coefficient (PTC) element, resistor, and a capacitor. A cover and base of the connecting package enclose and firmly secure connected circuit elements without needing a circuit board or filler material. The device design enables quick testing of the motor starter circuit and circuit elements after being enclosed by the housing.