Pump Unit Terminal Box Segmentation for Assembly

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Solution Overview

Problem

Existing pump units with electric motors face challenges in producing different electrical variants and assembling electronic components, as the integration of electrical connections and the drive motor in a one-piece housing complicates manufacturing and assembly.

Innovation Solution

A pump unit design featuring a terminal box with a tubular housing part open on both axial ends, allowing for easy assembly and integration of operating and display elements, with a cover element closing one end and a connection element on the circumference for electrical connections, reducing the number of individual parts and assembly steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the electrical connections and drive motor are integrated in a one-piece cast housing, then the manufacturing is simplified, but it becomes difficult to produce different electrical variants

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidelectrical variant flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The terminal box is divided into separate components: a tubular housing part that can be attached to the stator housing, and a cover element that closes the open end. This segmentation allows the electrical connections to be arranged flexibly within the terminal box while maintaining simple manufacturing of each individual component.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If the terminal box is open on both axial ends for easy assembly, then accessibility is improved, but sealing becomes more difficult

Engineering Contradiction:

Improveassembly accessibilityVSAvoidsealing complexity

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The terminal box is segmented into a tubular housing part and a cover element. The cover element seals the open end of the tubular housing part, creating a closed chamber while maintaining easy assembly through the open other end. This segmentation allows both accessibility and sealing requirements to be met.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If multiple individual parts are used for the terminal box, then adaptability is improved, but assembly complexity increases

Engineering Contradiction:

Improveelectrical configuration flexibilityVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The tubular housing part of the terminal box is designed as an integral component that combines multiple functions: it serves as the housing structure, provides mounting positions for electrical connections, and forms part of the sealing system. This merging reduces the number of individual parts while maintaining adaptability through the modular attachment to the stator housing.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2860403B1Pump unit

Publication Date: 2021.01.13 GRUNDFOS MANAGEMENT AS

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AI summary

The pump unit has an electric motor, which is located in a stator housing (6). A terminal box (12) has a tubular housing element that has an axial face connected to the axial face of the stator housing. An oppositely lying another axial face of the tubular housing element is closed by a cover element where operating elements and display elements are integrated. An electrical connecting element is arranged on the outer periphery of the tubular housing element. The tubular housing element is made form plastic.