Stator Plug Housing Connecting System with Two-Degree-of-Freedom Alignment
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Solution Overview
Problem
The existing connecting systems between stator assemblies and plug housings in electric motors require precise alignment, which slows down the mounting process and increases costs due to potential misalignments and stress on materials.
Innovation Solution
A connecting system that allows the stator assembly, plug housing, and stator housing to be movable relative to each other in at least two perpendicular directions, utilizing a plug housing receptacle with a fastener that provides two degrees of freedom, including radial and circumferential movement, and an elastic attachment in the axial direction to facilitate alignment and compensation of component tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the plug housing is fixed in a position on the stator assembly, then the alignment precision is improved, but the mounting time increases and costs increase
Solution Approach 1:
The plug housing is designed to be movable relative to the stator assembly through a receptacle structure that allows movement in at least two perpendicular directions. This dynamic connection enables the plug housing to automatically align with the stator assembly during mounting without requiring precise pre-alignment, thus improving mounting speed while maintaining alignment precision through self-adjustment.
2Manufacturing precision
If the plug housing is fixed in a position on the stator assembly, then the alignment precision is improved, but the quality decreases due to poorly aligned plug connections
Solution Approach 1:
The movable plug housing design allows the connection to adapt during mounting, ensuring proper alignment is achieved automatically. This dynamic adjustment capability improves connection quality by preventing forced misalignments while maintaining the precision benefits of a defined receptacle position.
3Ease of manufacture
If the stator assembly is moved toward the stator housing during mounting, then the mounting process is simplified, but stress on materials increases due to misalignment
Solution Approach 1:
The plug housing receptacle is designed to allow movement in at least two perpendicular directions, enabling the stator assembly to be moved toward the stator housing during mounting without creating misalignment stress. The movable connection absorbs positioning tolerances and prevents forced stresses on materials while simplifying the mounting process.
4Manufacturing precision
If the components are decoupled by movable design, then the tolerance compensation is improved, but the device complexity increases
Solution Approach 1:
The movable plug housing connection provides tolerance compensation through its ability to move in at least two perpendicular directions within the receptacle. This dynamic design achieves effective tolerance compensation with a relatively simple structure consisting of the receptacle and movable plug housing, avoiding excessive complexity while maintaining manufacturing precision.
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 design simplifies the mounting process by allowing relative movement between components, reducing the risk of misalignment and stress, while ensuring secure contact and alignment without static fixation, thus improving the quality and efficiency of the assembly.
Implementation Method 1
a fastener is arranged on the plug housing. The fastener engages with recesses in the plug housing receptacle when mounted
Implementation Method 2
an elastic attachment in the axial direction to facilitate alignment and compensation of component tolerances
Data Source
AI summary
A connecting system for a stator assembly (2) and a plug housing (3) can be inserted into an opening in a stator housing (4). A plug housing receptacle (6) is provided in the stator assembly (2). The plug housing (3) engages the housing receptacle such that it is movable relative to the stator assembly (2) in at least two perpendicular directions when mounted.