Electric Motor Wiring Plate with Preassembled Plug Element
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection devices for electric motors, such as those using plug-socket systems and insulation displacement contacts, require multiple manual steps for assembly, are space-intensive, and do not allow pre-assembly of external connection cables, leading to complexity and inefficiency in manufacturing and assembly.
Innovation Solution
A connection device featuring a preassembled plug element with insulation displacement contacts that can be plugged onto a circuit board parallel to the stator axis, eliminating the need for complex plug-socket systems and enabling pre-assembly of the connection cable, with conductor tracks designed as one-piece stamped and bent parts for reduced components and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug-socket systems are used for connecting winding ends to connection lines, then electrical connection is achieved, but multiple manual insertion processes are required which increase assembly time and complexity
Solution Approach 1:
The patent combines multiple separate plug-socket connections into a single integrated connector assembly. The connector housing integrates multiple contact elements and conductor tracks into one unified component that establishes all electrical connections simultaneously through a single insertion action, eliminating the need for multiple separate manual insertion processes.
Solution Approach 2:
The connector is pre-assembled with all contact elements, conductor tracks, and insulation components integrated into the housing before installation. This preliminary assembly allows the entire connection system to be installed in one operation, reducing assembly time and complexity while maintaining reliable electrical connections.
2Reliability
If individual bushings are introduced tangentially for connection, then electrical contact is established, but radial space is consumed which is limited in unfavorable installation positions
Solution Approach 1:
The patent transitions from tangential introduction of individual bushings to axial introduction of the integrated connector. By changing the insertion direction from radial-tangential to axial, the design utilizes the axial dimension for connection establishment, thereby conserving radial space that is often limited in unfavorable installation positions.
Solution Approach 2:
Multiple individual connection elements are merged into a single integrated connector assembly that introduces all electrical contacts through one axial insertion. This consolidation eliminates the need for multiple separate tangential introductions, reducing the radial space footprint while maintaining all necessary electrical contacts.
3Productivity
If insulation displacement contacts are used for simultaneous contacting of winding wires and connection cable, then direct electrical connection is established in one work step, but pre-assembly of external connection cable is not possible and conductor tracks are not provided for individual interconnection
Solution Approach 1:
The connector is segmented into distinct functional components: conductor tracks for individual wire interconnection, insulation displacement contacts for simultaneous contacting, and a modular housing structure. This segmentation allows the conductor tracks to provide individual interconnection paths while the insulation displacement contacts enable rapid assembly, and the modular design permits pre-assembly of the external connection cable.
Solution Approach 2:
The integrated connector performs multiple functions: it provides individual interconnection through conductor tracks, enables simultaneous contacting via insulation displacement contacts, and allows pre-assembly of connection cables. This multi-functionality resolves the contradiction by combining the advantages of both approaches into a single versatile device.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies the manufacturing and assembly process by allowing pre-assembly of the connection cable and reducing the number of components, while ensuring a secure and efficient electrical connection even in unfavorable installation positions.
Implementation Method 1
The insulation displacement contacts, when the plug element is plugged in, make direct contact with the contact sections at the ends of the conductor tracks
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a connecting device (2) for an electric motor, particularly an external rotor motor, to connect ends of a stator winding to a connecting lead (65). Said connecting device (2) is composed of a wiring plate (4) which is arranged on a plane extending in a radial direction relative to the stator axis and within a circumferential circle defined by a stator diameter, and which is provided with terminal areas for contacting the connecting lead (65) as well as shaped strip conductor guides (14) and strip conductors (6) with terminal lugs (38) for contacting the stator winding. A plug element (10) is provided which can be pre-assembled on the connecting lead (65) and comprises insulation displacement contacts (68) that contact the connecting lead (65). The plug element (10) can be mounted on the wiring plate (4) parallel to the stator axis such that the insulation displacement contacts (68) contact the terminal areas of the strip conductors (6) embodied as contacting sections (32a, 32b).