Motor Terminal Plate Coupling Without Ultrasonic Welding
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Solution Overview
Problem
The existing motor designs face challenges in assembling the terminal part due to difficulties in managing the welding portion during ultrasonic welding, which results in complex processes and potential deviations in the terminal part's position.
Innovation Solution
The motor design incorporates a terminal part that can be easily assembled with a plate without the need for ultrasonic welding or separate fastening members, utilizing a body part with ribs and protrusions to securely couple the terminal part to the plate and housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding is used to couple the terminal part to the plate, then the coupling strength is improved, but the process complexity increases and position precision deteriorates
Solution Approach 1:
The patent replaces the ultrasonic welding process with a mechanical coupling system consisting of a coupling structure with positioning protrusions and corresponding positioning grooves. This mechanical interface eliminates the need for complex welding equipment and processes while achieving secure attachment between the terminal part and plate.
Solution Approach 2:
The coupling structure acts as an intermediary element between the terminal part and the plate. It features positioning protrusions that fit into positioning grooves on the plate, providing a standardized mechanical interface that simplifies assembly while maintaining strong coupling without requiring welding.
2Strength
If ultrasonic welding is used to couple the terminal part to the plate, then the coupling strength is improved, but the position precision of the terminal part deteriorates
Solution Approach 1:
The coupling structure incorporates pre-formed positioning protrusions and positioning grooves that are manufactured in advance with precise dimensions. This preliminary positioning feature ensures accurate alignment of the terminal part with the plate before final assembly, eliminating position deviation that occurs during welding processes.
Solution Approach 2:
By replacing the welding process with a mechanical positioning and coupling system, the patent achieves superior position precision. The rigid mechanical interface of positioning protrusions fitting into grooves provides exact alignment without the thermal distortion and position shift inherent in ultrasonic welding.
3Reliability
If a separate fastening member is used to couple the terminal part to the plate, then the coupling reliability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the fastening function directly into the terminal part structure by integrating the coupling structure with positioning protrusions. This eliminates the need for separate fastening members such as screws or clips, reducing the total number of components while maintaining reliable mechanical coupling between the terminal part and plate.
Solution Approach 2:
The coupling structure serves multiple functions: it provides mechanical attachment, ensures precise positioning, and enables easy assembly and disassembly. By integrating these functions into a single integrated structure rather than using separate fastening members, the patent reduces overall device complexity while enhancing coupling reliability.
Data Source
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AI summary
The present invention may provide a motor including a housing, a stator disposed in the housing, a rotor disposed in the stator, a busbar disposed on the stator, a plate disposed on the busbar, and a terminal part including a body part in contact with the plate and a protruding part protruding from the body part and disposed on the plate, wherein a part of the body part is disposed between the housing and the plate in a radial direction.