Terminal Holder Groove Structure for Motor Lead Wire Retention
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Solution Overview
Problem
Existing motors require manual intervention for lead part insertion due to variations in wire diameter caused by tension during coil formation, leading to potential deformation of guide grooves and inefficiencies in automated assembly.
Innovation Solution
A motor design featuring an accommodation groove with a rib and locking protrusion that temporarily holds the lead part, allowing for easy insertion and stable retention without press-fitting, enabling automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead part is press-fitted into the guide groove to temporarily hold it, then the lead part can be retained in the groove, but the guide groove may be deformed and widened, causing adjacent grooves to narrow and making subsequent insertions difficult
Solution Approach 1:
The terminal holder is divided into multiple independent guide grooves, each equipped with its own rib and locking protrusion. This segmentation allows each groove to function independently, preventing deformation from affecting adjacent grooves. The rib and locking protrusion are positioned to provide localized support and retention without requiring excessive press-fit force that would deform the groove.
Solution Approach 2:
The rib and locking protrusion are pre-positioned on the terminal holder to prepare for lead part insertion. The rib provides preliminary guidance and support, while the locking protrusion is positioned to engage with the lead part before full insertion, distributing the retention force and preventing groove deformation during the pressing operation.
2Productivity
If automated machines are used to press-fit lead parts into guide grooves, then assembly efficiency can be improved, but the press-fit load may be insufficient or excessive, requiring manual intervention and reducing efficiency
Solution Approach 1:
The guide groove structure parameters are optimized by positioning the rib and locking protrusion at specific locations. The rib width, locking protrusion height, and their spacing are designed to match the lead part dimensions, creating an optimal press-fit condition that requires neither excessive nor insufficient force. This allows automated machines to reliably perform the insertion without manual intervention.
Solution Approach 2:
The rib acts as an intermediary element between the guide groove walls and the lead part. It provides a controlled interface that distributes the press-fit force evenly, preventing localized deformation while ensuring secure retention. This intermediary structure enables automated machines to apply consistent force without risking groove deformation or insertion failure.
3Productivity
If multiple lead parts are inserted simultaneously into multiple guide grooves, then productivity can be improved, but the press-fitting process may deform the guide grooves, requiring rework
Solution Approach 1:
Each guide groove is equipped with its own rib and locking protrusion, creating independent retention systems. This segmentation ensures that the press-fit operation in one groove does not affect adjacent grooves, allowing multiple lead parts to be inserted simultaneously without mutual interference or cumulative deformation effects.
Solution Approach 2:
The rib and locking protrusion are pre-positioned to provide immediate support and alignment for each lead part during simultaneous insertion. This preliminary positioning ensures that each lead part is retained reliably without requiring excessive force, maintaining groove dimensional stability even during batch insertion operations.
Data Source
AI summary
A motor includes: a terminal, including a slit where a winding drawn out from a coil is crimped; and a terminal holder, holding the terminal. The terminal holder includes: an accommodation groove, formed between a first sidewall and a second sidewall arranged at predetermined intervals in a width direction orthogonal to an extension direction of the winding, and accommodating the winding; a rib, provided on a portion of the first sidewall in the extension direction, and reducing a width dimension of the accommodation groove; and a locking protrusion, provided on the second sidewall side at a position offset in the extension direction from the rib, and locking the winding accommodated in the accommodation groove.