Electric Motor Terminal Pin Insulation via Height Difference Surface
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Solution Overview
Problem
Existing electric motor assembly techniques require significant manpower and are prone to inaccuracies, with insufficient insulation between the circuit board and the bracket leading to potential short circuits, especially under high load conditions.
Innovation Solution
The electric motor design features a stator embedded in synthetic resin with terminal pins erected on a height difference surface, accompanied by concave portions for enhanced insulation and easy assembly, allowing direct connection of the circuit board and providing a wide insulation space to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If only an insulating sheet is inserted between the circuit board and the bracket, then the assembly process is simple, but the insulation distance is insufficient and short circuits may occur under high load
Solution Approach 1:
The patent introduces a height difference (vertical dimension) between the circuit board mounting surface and the bracket, creating a stepped structure. This dimensional change provides sufficient insulation distance without complicating the assembly process, as the height difference is built into the molded structure itself rather than requiring additional insulation components.
Solution Approach 2:
The synthetic resin compact acts as an intermediary structure between the circuit board and the bracket. By molding the circuit board mounting surface at a different height than the bracket surface, the resin compact provides both mechanical support and electrical insulation, eliminating the need for separate insulating sheets while ensuring adequate insulation distance.
2Ease of manufacture
If the stator is integrally molded with synthetic resin using guide holes and pins, then positioning is easier, but the mold and terminal pin may contact and damage the pin if initial positions are inconsistent
Solution Approach 1:
The patent provides beforehand cushioning by designing the terminal pin to protrude beyond the stator surface, creating a buffer zone. This protrusion allows the pin to make contact first during mold closing, absorbing the impact and preventing damage to the pin or mold, while still enabling easy positioning through the guide holes.
Solution Approach 2:
The terminal pin is preliminarily positioned to protrude from the stator surface before mold closing. This preliminary positioning ensures that the pin is already in place and can guide the mold closing process, preventing misalignment and potential damage while maintaining the ease of positioning provided by the guide holes.
3Ease of operation
If the terminal pin is erected on the stator surface, then connection to the circuit board is simplified, but the insulation distance to the bracket is reduced increasing short circuit risk
Solution Approach 1:
The patent resolves this contradiction by utilizing the vertical dimension through a height difference surface. The circuit board is mounted on a surface that is at a different height than the bracket surface, allowing the terminal pin to protrude and connect to the circuit board while maintaining sufficient vertical insulation distance from the bracket. This dimensional approach enables both easy connection and reliable insulation simultaneously.
Data Source
AI summary
A gap surface (225) on which a circuit board (5) for driving control is mounted is provided between a first inner surface (222) and a second inner surface (223), a tip end of a terminal pin (6) is projected in a part of the gap surface (225), and further a first concave portion (228) formed by recessing surroundings of the terminal pin (6) in an axis line direction of the terminal pin is provided in the gap surface (225). Thus, an electric motor can be assembled in a short period of time.