Electric Motor Terminal Structure for Solder-Free Stator Assembly
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Solution Overview
Problem
Existing electric motors have complex manufacturing processes and high production costs due to reliance on soldering and additional circuit boards for connecting stator housing and stator assembly.
Innovation Solution
An electric motor design featuring a stator housing with a first conductive terminal and guiding structure that allows for snap-fit connection of the stator assembly, eliminating the need for soldering and additional circuit boards, and incorporating a bobbin with interlocking structures for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering and additional circuit boards are used to connect stator housing and stator assembly, then connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the connector structure directly into the stator housing, merging the housing and connection components into a single integrated part. This eliminates the need for separate circuit boards and reduces the number of assembly steps while maintaining reliable electrical connections between the stator housing and stator assembly.
Solution Approach 2:
The patent extracts and eliminates the soldering process and additional circuit boards from the assembly, replacing them with a direct mechanical and electrical connection system built into the stator housing structure, thereby simplifying the manufacturing process.
2Reliability
If soldering and additional circuit boards are used to connect stator housing and stator assembly, then connection reliability is improved, but production cost increases
Solution Approach 1:
The connector structure is merged with the stator housing as an integrated component, eliminating the need for separate circuit boards and reducing the number of parts that need to be manufactured, purchased, and assembled, thereby reducing production costs while maintaining connection reliability.
Solution Approach 2:
The patent removes the costly soldering process and additional circuit board components from the manufacturing system, replacing them with a simpler, more cost-effective integrated connection structure that reduces material and labor costs.
3Ease of manufacture
If snap-fit connection is used to connect stator assembly to stator housing, then ease of manufacture is improved, but connection strength may be reduced
Solution Approach 1:
The snap-fit connector is integrated into the stator housing structure, combining mechanical support and electrical connection functions into a single robust structure that maintains strong connections while enabling easy assembly and disassembly.
Solution Approach 2:
The connector structure appears to use composite construction combining rigid structural elements for mechanical strength with conductive elements for electrical connection, creating a multi-functional component that satisfies both strength and ease of manufacture requirements.
Data Source
AI summary
An electric motor includes a stator housing, a first conductive terminal, a stator assembly and a rotor assembly. The first conductive terminal is disposed on the stator housing and includes a first end portion and a second end portion. The first end portion is located in a receptacle for receiving the stator assembly and has a first insertion opening. The second end portion is located in a connector structure. The guiding structure has a second insertion opening and an end surface arranged around the second insertion opening and resting against the first end portion of the first conductive terminal. The first insertion opening is narrower than the second insertion opening. The stator assembly includes a coil and a second conductive terminal connected to the coil and inserted into the first and second insertion openings. The rotor assembly is positioned to face the stator assembly.