Stator Terminal Assembly for Stable Motor Lead Wire Soldering
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Solution Overview
Problem
The lead wire of a motor is prone to warping and unstable connection due to manufacturing tolerances, making soldering difficult and unsatisfactory, especially when trying to fit into slots for fixation before soldering.
Innovation Solution
A stator assembly design with studs and positioning surfaces to secure lead wires, including a terminal block with studs and slots, and a protective housing to stabilize the lead wires during soldering, ensuring precise alignment and reduced warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the lead wire is fixed in a slot before soldering, then the lead wire position is constrained, but manufacturing tolerances cause the lead wire to become too loose or too tight, resulting in warping and poor soldering
Solution Approach 1:
The stud is bent toward the lead wire before soldering to pre-position the lead wire correctly. This preliminary action ensures the lead wire is properly aligned and constrained in the optimal position before the soldering process begins, eliminating positioning errors that would otherwise occur during or after soldering due to manufacturing tolerances
Solution Approach 2:
The stud is designed to be movable and bendable during assembly, allowing it to adapt to variations in lead wire position. The stud can be bent to different degrees to accommodate manufacturing tolerances, providing dynamic adjustment capability that ensures reliable lead wire positioning regardless of initial positioning variations
2Ease of manufacture
If the lead wire is left loose without pre-fixation, then the terminal structure is simpler, but the lead wire warps and becomes difficult to fit with the terminal, resulting in unsatisfactory soldering
Solution Approach 1:
The bent stud serves as both a positioning element and a self-adjusting mechanism. During assembly, the stud automatically guides and constrains the lead wire into the correct position through its bent shape, enabling the terminal structure to self-correct positioning errors without requiring additional fixing fixtures or complex assembly procedures
Solution Approach 2:
The bent stud acts as an intermediary element between the terminal and the lead wire. It provides a mechanical interface that translates the terminal's positioning requirements into direct physical constraint on the lead wire, ensuring reliable alignment and contact during soldering while maintaining structural simplicity
Data Source
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AI summary
A stator assembly, a motor and a washing appliance are disclosed. The stator assembly (1000) includes: an insulating frame (100); a winding (110), wound around the insulating frame (100) and comprising a plurality of lead wires (111); a terminal block (120), on which a plurality of mounting positions (121) are arranged at intervals; a socket (130), connected to the terminal block (120) and covering the plurality of mounting positions (121); and a first terminal (200) and a second terminal (300), respectively mounted at corresponding one of the plurality of mounting positions (121), wherein the first terminal (200) and the second terminal (300) are respectively connected to the corresponding one of the plurality of lead wires (111), the first terminal (200) comprises a first wire bonding portion (210) and a first tab (220) extending out of the socket (130), and a first stud (211) and a second stud (212) are spaced apart from each other on one side of the first wire bonding portion (210). One of the plurality of lead wires (111) is between the first stud (211) and the second stud (212), and the first stud (211) and/or the second stud (212) are/is configured to be bent toward the one of the plurality of lead wires (111) to limit a position of the one of the plurality of lead wires (111).