Thermal Terminal Application for Motor Winding Connections
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Solution Overview
Problem
Existing methods for connecting electrical conductors in windings, such as those in electric motors, are inefficient due to manual operation, high variability, and limitations in handling multiple conductors or varying cross-sections, leading to reliability and scalability issues.
Innovation Solution
A method and device that apply an electrical terminal directly to conductors using a channel-shaped housing with heat and pressure to remove insulation and form a reliable connection, utilizing a crimp-like portion for conductors and a cable terminal-like portion for connection to a power source, allowing for flexible and efficient connections without intermediate elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual flame method is used to remove insulation and join conductors, then connection can be achieved, but execution time is very long and reliability is scarce
Solution Approach 1:
The patent replaces the manual mechanical flame torch method with an automated thermal processing system. The device uses controlled heating elements to simultaneously heat multiple conductors and the electrical terminal, automatically removing insulation and forming connections without manual intervention, thus reducing execution time while maintaining reliability
Solution Approach 2:
The patent applies preliminary action by pre-positioning the electrical terminal on the conductors before final connection formation. The device holds the terminal in place during the heating process, ensuring proper alignment and preventing movement that could compromise connection quality, thereby improving reliability while enabling automated processing
2Ease of manufacture
If mechanical cutters and abrasive brushes are used to remove insulating layer, then insulation removal can be achieved, but the process is time-demanding and complex
Solution Approach 1:
The patent replaces mechanical cutting and abrasive methods with thermal processing. The heating elements directly contact the conductors and electrical terminal, using heat to remove insulation and form connections in a single integrated step, eliminating the need for separate mechanical removal operations and significantly reducing processing time
Solution Approach 2:
The patent changes the physical parameter approach from mechanical force (cutting, abrasion) to thermal energy (heating). By controlling temperature and heat application duration, the system achieves insulation removal and connection formation more efficiently, simplifying the manufacturing process while reducing time requirements
3Quantity of substance
If crimp with teeth or projections is used to cut insulation and produce contact, then connection can be achieved, but it limits the number of conductors that can be joined
Solution Approach 1:
The patent segments the heating function into multiple independent heating elements that can simultaneously process multiple conductors. Each heating element independently heats a conductor and the electrical terminal, allowing parallel processing of many conductors without compromising the quality of individual contacts, thus enabling joining of large numbers of conductors while maintaining reliability
Solution Approach 2:
The electrical terminal design incorporates multiple contact points and a structure that can accommodate varying numbers and sizes of conductors. The universal design allows the same terminal and device to handle different conductor configurations, enabling the joining of multiple conductors simultaneously without sacrificing contact quality
4Reliability
If hot crimping method is used with heating elements, then insulation removal and plastic deformation can be achieved, but the crimp flexibility and shape limit its functionality
Solution Approach 1:
The patent employs a flexible electrical terminal that can be dynamically positioned and shaped during the connection process. The terminal material and structure allow it to adapt to different conductor sizes and configurations, enabling the same device to reliably connect various conductor types while maintaining strong connections through controlled thermal processing
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 method reduces electrical resistance and fragility, enhances reliability, and simplifies the connection process, enabling faster, more consistent, and cost-effective connections suitable for industrial-scale production and various conductor sizes.
Implementation Method 1
a flame is applied to initially burn the insulating enamel and remove it from the conductors
Implementation Method 2
the use of a flame to initially burn the insulating enamel
Implementation Method 3
the tubular element is pressed and successively heated to obtain results similar to those obtainable through the use of a crimp
Implementation Method 4
applying heat and pressure in such a way as to compact and/or join said end portions of said one or more conductors and said housing portion of said electrical terminal
Data Source
AI summary
The invention provides a method for applying an electrical terminal to one or more conductors, possibly provided with an external electrical insulation layer, comprising the following steps: placing the end portions of the conductors in a housing portion of the terminal; applying heat and pressure in such a way as to compact and/or join the end portions of the conductors and the housing portion of the electrical terminal and to remove any respective electrical insulation layers at least at the level of the housing portion of the electrical terminal. The application of pressure and heat causes the opposite walls to close on the end portions of the conductors. Said electrical terminal comprises an electrical connection portion that extends from the housing portion. The invention also concerns a device or piece of equipment for the application of an electrical terminal, a metal element and an electrical terminal.