Motor Wire Cover Press-Fit for Precise Lead Wire Alignment
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Solution Overview
Problem
Existing electric motor designs face challenges in achieving high precision in the leading-out direction of lead wires from the motor housing, leading to deviations in terminal positions, which hinder automatic connection to electrical units and compromise electrical insulation.
Innovation Solution
The design incorporates a wire cover with crush ribs and a press-fitted configuration within the motor housing's leading-out holes, ensuring precise alignment and reducing positional deviations of lead wires through the use of hard insulating resin and symmetrical contour shapes for the wire cover and leading-out holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the inside diameter of the wire leading-out hole is set sufficiently greater than the outside diameter of the lead wires to facilitate assembly, then the ease of manufacture is improved, but the manufacturing precision of lead wire positioning deteriorates
Solution Approach 1:
A wire cover is introduced as an intermediary component between the lead wires and the wire leading-out hole. The wire cover has through-holes that guide the lead wires, ensuring precise positioning while the wire cover itself is press-fitted into the wire leading-out hole. This intermediary structure allows the hole to be larger for ease of assembly while maintaining precise lead wire positioning through the wire cover's through-holes.
Solution Approach 2:
The positioning function is segmented from the wire leading-out hole structure to a separate wire cover component. The wire cover contains the through-holes for lead wire guidance, while the wire leading-out hole serves primarily for structural support and electrical insulation. This segmentation allows each component to be optimized independently - the hole for ease of manufacture and the wire cover for positioning precision.
2Manufacturing precision
If a hard insulating resin wire cover is press-fitted into the wire leading-out hole to improve lead wire alignment, then the manufacturing precision is improved, but the wire cover may be damaged during assembly
Solution Approach 1:
The wire cover is designed with localized crush ribs at specific positions rather than uniform thickness throughout. The crush ribs are positioned at locations where pressing force is applied during assembly, allowing these specific areas to deform and absorb stress. The main body of the wire cover maintains sufficient thickness and strength to prevent damage, while the crush ribs provide the necessary compliance for press-fitting.
Solution Approach 2:
The crush ribs serve as pre-designed stress absorption zones that beforehand cushion the pressing force during assembly. By incorporating these rib structures in advance, the design anticipates the stress concentration that would occur during press-fitting and provides a controlled deformation path, preventing unexpected damage to the wire cover while ensuring proper installation.
3Manufacturing precision
If the wire cover is made from hard insulating resin to maintain electrical insulation and precision, then the manufacturing precision and electrical insulation are improved, but the device complexity increases
Solution Approach 1:
The wire cover is designed to perform multiple functions simultaneously: it provides precise positioning for lead wires through its through-holes, maintains electrical insulation between the lead wires and the wire leading-out hole, and serves as a structural component that is press-fitted into the motor housing. By consolidating these multiple functions into a single component, the design avoids increasing overall device complexity while achieving the desired precision and insulation.
Solution Approach 2:
The wire cover combines several previously separate functions into one integrated component: positioning guidance, electrical insulation, and structural support. This merging eliminates the need for separate positioning fixtures, insulation barriers, and support structures, thereby maintaining simplicity while achieving high precision and reliable insulation.
Data Source
AI summary
Provided is an electric motor in which it is possible to accurately leading-out terminal sections of a magnet wire that constitutes a stator coil in a prescribed leading-out direction as lead wires. A wire cover formed from a hard insulating resin is press-fitted into a wire leading-out hole provided in an end member that closes one end of a motor housing, and lead wires are led out to an exterior through through-holes provided in the wire cover. Crush ribs are provided to side surfaces of a head part of the wire cover, and, due to crushing of the crush ribs and press-fitting of the wire cover into the wire leading-out hole, the wire cover is prevented from inclining within the wire leading-out hole and a leading-out direction of the lead wires is prevented from deviating from the prescribed leading-out direction.