Motor Varistor Mounting via Offset Radial Terminals
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Solution Overview
Problem
Existing motor designs require increased labor and mounting space due to the need to bend varistor legs and manage their angle, leading to a larger motor size and complexity in terminal connections.
Innovation Solution
The motor design incorporates offset element connection portions with grooves for press-fitting varistor legs, eliminating the need for bending and allowing for a more compact layout, reducing labor and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the legs of the varistor are bent toward the element connection portion side to connect the varistor across the pair of first terminals, then the varistor can be mounted, but the labor increases and the mounting space increases leading to the motor increasing in size
Solution Approach 1:
Instead of bending the varistor legs to achieve connection, the patent inverts the approach by designing the element connection portions to extend in opposite radial directions. This allows the legs to be pressed straight into the connection portions without bending, eliminating the complex leg bending process while maintaining proper electrical connection.
Solution Approach 2:
The patent changes the spatial arrangement from a planar configuration requiring leg bending to a three-dimensional configuration where connection portions extend in opposite radial directions. This dimensional change allows direct press-fit connection without leg deformation, reducing both labor and mounting space.
2Ease of manufacture
If the legs of the varistor are bent in a direction so as to separate away from each other, then the varistor can be connected across the terminals, but the mounting space of the varistor as viewed along the axial direction increases
Solution Approach 1:
Rather than bending legs outward to achieve terminal connection, the patent extends the element connection portions in opposite radial directions. This inverted approach allows the varistor to be mounted with legs extending axially without bending, significantly reducing the mounting space in the axial direction.
Solution Approach 2:
The patent transitions from a two-dimensional mounting approach (requiring radial leg bending) to a three-dimensional approach where connection portions are distributed in opposite radial directions. This allows compact axial mounting without leg separation, reducing the overall motor size.
3Device complexity
If element connection portions are disposed facing a direction orthogonal to the radial direction, then terminals can be formed, but the need to bend legs increases labor and requires angle management
Solution Approach 1:
Instead of having element connection portions face orthogonal directions and requiring leg bending, the patent extends the connection portions in opposite radial directions. This inversion eliminates the need for angle management and leg bending, simplifying the manufacturing process.
Solution Approach 2:
The patent employs asymmetric positioning of element connection portions extending in opposite radial directions, which naturally accommodates the varistor legs without requiring symmetric bending or complex angle management, thereby simplifying manufacturing.
Data Source
AI summary
There is provided a motor, the motor comprising (1) a brush unit that is provided at one axial direction side of a motor main body, and that includes a first brush and a second brush, (2) a pair of power supply terminals that are provided at the brush unit, that are respectively electrically connected to either the first brush or the second brush, and that include connector connection portions to which external connectors connect and that extend out toward another axial direction side of the motor main body at respective other end sides of the power supply terminals, and (3) a pair of element connection portions that are respectively provided at the other end sides of the power supply terminals, and that are disposed offset from each other in the radial direction of the motor main body.