Stator Terminal PCB Contacting Using Horizontal IDC Slots
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Solution Overview
Problem
Existing methods for electrically contacting stator windings to a printed circuit board in pumps and electric motors are cumbersome, particularly when using insulation displacement contacts, as the axial insertion of winding wire end sections can be difficult and requires accessible areas for press-fitting tools.
Innovation Solution
The use of slot-shaped openings in insulation displacement contacts that allow parallel insertion of winding wire end sections to the printed circuit board, facilitated by a tangential press-fitting process using a two-part press-fitting tool, simplifies the manufacturing process and ensures reliable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation displacement contacts are used with axial insertion of winding wire end sections, then electrical contact between stator and printed circuit board is achieved, but the assembly process becomes difficult and requires accessible areas for press-fitting tools
Solution Approach 1:
The patent inverts the traditional axial insertion approach by implementing lateral insertion of winding wire end sections into the insulation displacement contacts. The slot-shaped openings are oriented laterally relative to the printed circuit board surface, allowing wires to be inserted from the side rather than from the axial direction. This inversion of the insertion direction eliminates the need for difficult axial access and simplifies the press-fitting process.
Solution Approach 2:
The patent changes the dimension of insertion by transitioning from axial (vertical) insertion to lateral (horizontal) insertion. The slot-shaped openings extend laterally parallel to the printed circuit board surface, creating a new dimensional approach for wire insertion. This dimensional change allows press-fitting tools to access the contacts from the side, significantly improving manufacturability while maintaining electrical contact reliability.
2Reliability
If traditional axial press-fitting method is used, then electrical contact is established, but the process complexity increases and automation becomes difficult
Solution Approach 1:
The patent inverts the press-fitting approach by applying lateral pressure instead of axial pressure. The press-fitting tool applies force from the side, perpendicular to the printed circuit board surface, rather than from the axial direction. This inverted approach simplifies the tooling requirements and makes the process more suitable for automation while maintaining reliable electrical contact.
Solution Approach 2:
The patent changes the critical parameters of the press-fitting process by altering the insertion direction and force application direction from axial to lateral. The slot-shaped openings are designed to receive wires laterally, and the press-fitting tool is configured to apply lateral force. This parameter change reduces process complexity and facilitates automation while preserving contact reliability.
3Reliability
If axial insertion approach is used, then electrical connection is achieved, but manufacturing time and accessibility requirements increase
Solution Approach 1:
The patent inverts the insertion methodology by using lateral insertion instead of axial insertion. This inversion allows for more direct and efficient wire placement into the insulation displacement contacts, reducing the time required for assembly. The lateral approach eliminates the need for complex positioning and alignment procedures associated with axial insertion.
Solution Approach 2:
The patent changes the insertion parameter from axial direction to lateral direction, which significantly improves assembly efficiency. The slot-shaped openings are oriented to receive wires laterally, allowing for faster and easier insertion. This parameter change reduces assembly time while maintaining reliable electrical connection, making the manufacturing process more efficient.
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
This approach simplifies the assembly process, enhances process reliability, and allows for easy automation by enabling parallel insertion and tangential press-fitting of winding wire end sections, reducing complexity and improving accessibility for the press-fit tool.
Implementation Method 1
the winding wire end sections are electrically contacted directly with a printed circuit board at the end surfaces through insulation displacement contacts each including at least one slot-shaped opening for insertion of a winding wire end section
Data Source
AI summary
A pump includes an electric motor with a rotor mounted rotatably about an axis of rotation and circumferentially surrounding a stator that includes a stator core and coils wound on the stator core. The windings are defined by a winding wire with winding wire end sections electrically contacted directly with a printed circuit board at an end surface through insulation displacement contacts each including at least one opening for insertion of a winding wire end section, the at least one opening being a slot extending parallel or substantially parallel to a surface of the printed circuit board.