Motor Terminal Cover Layout Without Bus Bar Assembly
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Solution Overview
Problem
Existing motors face challenges with multiple fusing processes, increased part count, and enlarged size due to components like worm shafts and worm wheels, particularly when integrated with vehicle components.
Innovation Solution
An actuator design that omits the bus bar assembly by using a terminal cover with a body part and side part to connect coils directly to terminals, reducing the need for fusing processes and components, and incorporating a rotor, stator, and rotational shaft configuration to minimize size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar assembly with multiple fusing processes is used to connect coils to terminals, then reliable electrical connection is achieved, but the number of parts increases and manufacturing complexity increases
Solution Approach 1:
The terminal cover integrates multiple functions: it serves as both the protective cover and the electrical connection component. The terminals are directly formed on the terminal cover body, merging the bus bar function with the cover function, thereby eliminating the need for separate bus bar assemblies and reducing the number of parts while maintaining reliable electrical connections.
Solution Approach 2:
The terminal cover performs multiple functions simultaneously: mechanical protection of internal components, structural support, and electrical connection. By incorporating terminals directly into the cover structure, the design achieves multi-functionality that reduces overall device complexity while ensuring reliable electrical pathways.
2Reliability
If multiple fusing processes are used to connect terminals to coils, then secure electrical connection is achieved, but manufacturing time and production cost increase
Solution Approach 1:
The terminals are pre-formed as integral parts of the terminal cover during the molding process. This preliminary formation of electrical connection points eliminates the need for subsequent fusing operations, thereby reducing manufacturing steps and improving production efficiency while maintaining connection reliability.
Solution Approach 2:
The invention extracts and eliminates the fusing process from the manufacturing sequence by designing terminals that are directly formed on the terminal cover. This removal of the fusing step reduces both manufacturing time and production costs while maintaining secure electrical connections through the integrated terminal design.
3Adaptability or versatility
If worm shaft and worm wheel are added to change power transmission direction, then vertical power transmission is achieved, but the actuator size increases
Solution Approach 1:
The terminal cover extends in the vertical direction with terminals positioned to receive coils from above. This vertical arrangement of electrical connections allows the motor to maintain a compact horizontal footprint while achieving the required power transmission orientation, effectively using vertical space to reduce overall actuator volume.
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 design eliminates defects from fusing processes, reduces the actuator's length, and decreases the number of fusing points, thereby minimizing the overall size and component count while potentially lowering manufacturing costs.
Implementation Method 1
the terminal cover includes a body part covering an upper portion of the stator
Data Source
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AI summary
A motor comprising a rotational shaft (100); a rotor (200); a stator (300) disposed on an outside of the rotor; a coil wound around the stator; and a terminal cover (800) covering an upper portion and a portion of the side surface of the stator, wherein the terminal cover comprises a body part (810), a side part (820) and a terminal (830) disposed inward of the side part, wherein the body part comprises a first body part (811) and a second body part (812), wherein the first body part comprises an upper surface and a protruding portion, wherein the terminal comprises terminal pins (832) disposed outside of the protruding portion of the first body part, and being fused with the coil, and wherein an outer circumferential surface of the first body part extends farther outward in the radial direction than each terminal pin of the plurality of terminal pins.