Segmented Splice Terminal for Magnet Wire Positioning
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Solution Overview
Problem
Existing magnet wire terminals face difficulties in properly positioning and terminating magnet wires and lead wires due to space constraints, leading to compromised electrical connections if wires are not correctly aligned, which can result in malfunctioning electrical devices.
Innovation Solution
A splice terminal with a first closed section for magnet wires and a second open section for both magnet and lead wires, featuring positive stop surfaces and serrations to ensure accurate positioning and secure crimping, ensuring proper electrical connection and retention of wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single saddle terminal is used to accommodate both magnet wires and lead wires, then the device complexity is reduced, but the manufacturing precision and reliability of wire positioning deteriorate
Solution Approach 1:
The terminal is divided into two distinct saddles: a first saddle configured to receive only magnet wires and a second saddle configured to receive only lead wires. This segmentation ensures that each wire type is positioned in its designated area, preventing mixing and ensuring proper alignment during the crimping process, thereby maintaining manufacturing precision while using a relatively simple terminal structure.
2Reliability
If the terminal is crimped to secure wires, then the reliability of electrical connection is improved, but the magnet wire positioning may be compromised if lead wires encompass the magnet wire
Solution Approach 1:
By providing separate saddles for magnet wires and lead wires, the terminal ensures that lead wires cannot encompass magnet wires during insertion. The first saddle is dedicated to magnet wires with serrations for electrical connection, while the second saddle is dedicated to lead wires, eliminating the risk of positioning errors that would compromise crimping reliability.
3Ease of operation
If space considerations are reduced to allow easier wire positioning, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The terminal uses a segmented design with two distinct saddles that are visually and physically differentiated. The first saddle has serrations and is configured for magnet wires, while the second saddle is configured for lead wires. This clear segmentation makes it easy for operators to position the correct wire in the correct saddle, improving ease of operation without requiring excessive space or complex mechanisms.
Data Source
AI summary
A splice terminal for connecting a magnet wire to a lead wire. The splice terminal includes a first closed section and a second open section. The first closed section has a first section bottom wall, first section side walls and a first section top wall. An opening is provided between the first section bottom wall, the first section side walls and the first section top wall. The opening is configured to receive the magnet wire therein. The opening has a height between the first section bottom wall and the first section top wall which is larger than the diameter of the magnet wire. The second open section has a second section bottom wall and second section side walls. The second section is configured to receive the magnet wire and the lead wire therein.