Motor Terminal Guide Insulating Distance via Separate Insert Nuts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for fixing motor terminals in Hybrid Starter Generator (HSG) motors, which involve injection molding of the terminal guide and insert nut together, result in insufficient insulating distance due to the presence of an injection hole, leading to potential short circuits from moisture and foreign objects, necessitating additional insulating components that increase manufacturing costs and weight.
Innovation Solution
A method and apparatus where the terminal guide is injection molded without an injection hole, featuring insertion grooves for separate insert nuts, and a connector with bus bars is used to secure the insert nuts, preventing separation and eliminating the need for an insulating block by maintaining the insulating distance between the terminal guide and motor cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal guide and insert nut are injection molded together, then the manufacturing process is simplified, but the insulating distance becomes insufficient due to the injection hole
Solution Approach 1:
The terminal guide and insert nut are separated into two independent components. The terminal guide is injection molded without an injection hole, and the insert nut is separately molded and then inserted into the terminal guide through a dedicated insertion groove, eliminating the need for an injection hole and maintaining insulating distance.
Solution Approach 2:
The injection hole is removed from the terminal guide design. Instead of molding the insert nut through an injection hole, a separate insertion groove is created on the terminal guide surface, allowing the insert nut to be inserted and fixed without compromising the insulating integrity of the terminal guide.
2Reliability
If an insulating block is added to maintain insulating distance, then insulation reliability is improved, but the number of parts and weight increase
Solution Approach 1:
The insulating function is integrated into the terminal guide itself by designing it without an injection hole and using the terminal guide's own structure to maintain insulating distance from the motor cover, eliminating the need for a separate insulating block component.
Solution Approach 2:
The terminal guide structure is designed to inherently maintain the required insulating distance from the motor cover through its own geometric features and positioning structures, without requiring additional insulating components.
3Ease of operation
If the insert nut is injection molded together with the terminal guide, then assembly is simplified, but the insert nut cannot be securely fixed without an injection hole
Solution Approach 1:
The terminal guide is pre-formed with an insertion groove during injection molding, which is specifically designed to receive and secure the separately molded insert nut. This preliminary preparation ensures that the insert nut can be firmly fixed through mechanical engagement without requiring an injection hole.
Data Source
AI summary
An apparatus for fixing a power line terminal may include a terminal guide configured to be mounted at one end of a motor cover to support a motor coil terminal and to have an upper surface provided with a plurality of insertion grooves, and a plurality of insert nuts configured to be inserted into the plurality of insertion grooves, the insert nuts manufactured separate from the terminal guide.