Plug-in Module Carrier Recesses for Motor Unit Assembly
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Solution Overview
Problem
The challenge in creating a plug-in module for motor vehicles' adjusting motors is ensuring secure and correct electrical contact within a plastic housing, which is cost-effective and requires minimal procedural complexity.
Innovation Solution
A plug-in module design featuring a carrier element with recesses for electrical plug elements, allowing for easy insertion and alignment, and a contact portion that is movable to compensate for positional errors, ensuring reliable engagement with motor unit connectors, thereby facilitating a cost-effective and efficient assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If electrical plug elements are embedded in plastic housing, then structural integration is improved, but manufacturing complexity increases
Solution Approach 1:
The plug-in module is divided into separate components: a plastic housing and separately mounted electrical plug elements. The carrier element provides recesses that receive the plug elements, which are then secured through insertion and fixing. This segmentation allows each component to be manufactured independently using simple processes, then assembled together, avoiding the complexity of embedding plugs directly in molded plastic.
Solution Approach 2:
The carrier element is pre-formed with recesses designed to receive the electrical plug elements. These recesses include opening through which plug elements can be introduced and holding portions for securing them. This preliminary preparation of the carrier element simplifies the subsequent assembly process and ensures proper positioning without requiring complex embedding operations.
2Reliability
If plug elements are securely fixed in plastic, then electrical contact reliability is improved, but assembly complexity increases
Solution Approach 1:
The carrier element's recesses are designed to automatically guide and position the electrical plug elements during insertion. The opening and holding portion structure enables the plug elements to self-align and secure themselves into the correct position without requiring complex external fixing mechanisms or precision alignment procedures.
Solution Approach 2:
The carrier element acts as an intermediary structure between the plastic housing and the electrical plug elements. It provides a simplified interface with pre-formed recesses that facilitate easy mounting and secure fixation of the plug elements, reducing the assembly complexity while ensuring reliable electrical contacts.
3Weight of moving object
If plug-in module is made from plastic, then weight is reduced, but mechanical strength decreases
Solution Approach 1:
The plug-in module uses a composite construction combining plastic housing with separately mounted electrical plug elements secured in the carrier element. This allows the lightweight plastic to provide the main structure while the metal plug elements provide the necessary electrical conductivity and mechanical strength for reliable connections, achieving optimal weight-to-strength ratio.
Data Source
AI summary
A plug-in module for a motor unit, in particular for an adjusting motor, the plug-in module having a plug for introducing into a housing of the motor unit. In addition, the plug has: a carrier element having at least one recess for a respective electrical plug element; and the plug element itself for engaging with the corresponding plug connector of the motor unit, the plug element being arranged into the recess. Furthermore, the recess includes: an opening via which a plug element can be introduced in the recess; and a holding section into which a securing zone of the plug element can be pressed.