Motor Terminal Housing Guide Plate Alignment
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Solution Overview
Problem
Conventional BLDC motors face issues with accurate assembly of terminal housings due to large gaps between the terminal housing coupling unit and the terminal housing, leading to potential separation during electric power application.
Innovation Solution
A terminal connection structure with a guide plate and hook portion design, where the hook portion is snap-fitted and larger than the hook member, and includes a regulation protrusion to prevent disengagement, allowing for precise alignment and secure attachment of the terminal housing to the power supply terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the terminal housing and insulator are injection molded with synthetic resin material, then manufacturing efficiency is improved, but a large gap is formed between the terminal housing coupling unit and terminal housing
Solution Approach 1:
The guide plate is pre-formed with guide protrusions that extend into the terminal housing during assembly, establishing precise positioning before the final connection is made. This preliminary guiding action ensures accurate alignment while maintaining the efficiency of injection molding.
Solution Approach 2:
The guide plate acts as an intermediary component between the insulator and terminal housing, featuring guide protrusions that fit into corresponding guide grooves. This intermediary structure bridges the gap between molded parts and achieves precise assembly without requiring post-molding adjustments.
2Adaptability or versatility
If a large gap is formed between the terminal housing coupling unit and terminal housing, then assembly flexibility is improved, but the terminal housing may be easily separated when electric power applying position is assembled
Solution Approach 1:
The connection structure is segmented into multiple functional elements: the guide plate with guide protrusions for positioning, the hook portion for engagement, and the regulation protrusion for securing. This segmentation allows each element to perform its specific function while working together to achieve both flexibility and reliability.
Solution Approach 2:
The hook portion is designed to elastically deform during assembly, allowing it to flex into the terminal housing and then maintain a secure engaged state. This dynamic behavior enables easy assembly while ensuring reliable connection under operational conditions.
3Ease of operation
If the hook portion is snap-fitted to the hook member, then assembly ease is improved, but precise alignment may be difficult to achieve
Solution Approach 1:
The guide protrusions on the guide plate perform preliminary alignment by fitting into guide grooves in the terminal housing before the hook portion engages. This preliminary positioning action ensures precise alignment is achieved automatically during the snap-fit assembly process.
Solution Approach 2:
The guide protrusions and guide grooves are designed to self-align during assembly, with the geometry of these features guiding the terminal housing into correct position relative to the guide plate. This self-aligning mechanism eliminates the need for separate alignment steps while maintaining assembly ease.
Data Source
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AI summary
A motor is provided, the motor including an insulator body (10) coupled to a stator core (30) wound with a plurality of coils applied with an electric power having mutually different polarities to prevent the coils and the stator core (30) from being short-circuited, a terminal housing coupling unit (20) integrally constituted with the insulator body (10), protruded to a circumferential direction and coupled to a terminal housing (100) supplying an external electric power, a terminal housing (100) coupled to the terminal housing coupling unit (20) to supply an electric power to the motor, a fixing unit (130) position-fixing the terminal housing (100) to the terminal housing coupling unit (20), and a regulation unit mounted on the fixing unit (130) to regulate a rotation angle of the terminal housing (100).