Electric Winch Terminal Mounting Assembly Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly process of electric winches is cumbersome and inefficient due to the manual mounting of terminal posts on the motor housing and the separate assembly of rotor and brush components, leading to low efficiency and potential electrical conductivity issues.
Innovation Solution
The design includes an insulating cover plate with through holes and inner bore columns to facilitate the external mounting of terminals, a limiting boss and insulating spacer to secure the motor housing, and sealing gaskets to prevent water ingress, allowing for simultaneous and efficient terminal mounting and improved leakproofness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If terminal posts are manually mounted on motor housing and rotor and brush components are assembled separately, then assembly flexibility is maintained, but assembly efficiency is reduced and electrical conductivity issues may occur
Solution Approach 1:
The patent merges the terminal mounting function with the motor housing structure by providing through-holes directly in the housing. This allows terminal posts to be mounted simultaneously with other components through the same housing structure, eliminating separate mounting operations and improving assembly efficiency while maintaining electrical insulation through the housing material.
Solution Approach 2:
The motor housing acts as an intermediary structure that simultaneously serves as the mechanical support for mounting terminal posts and as an electrical insulator. The through-holes in the housing allow terminal posts to pass through and be secured, while the housing material itself provides electrical insulation between the terminals and internal motor components.
2Reliability
If terminal posts are fixed separately to motor housing, then installation flexibility is maintained, but assembly time increases and electrical insulation may be compromised
Solution Approach 1:
The patent combines the electrical insulation function with the terminal mounting structure by using the motor housing itself as the insulating barrier. The terminal posts pass through pre-provided through-holes in the housing and are secured from the outside, eliminating the need for separate insulating materials or complex mounting procedures. This simultaneous achievement of insulation and mounting significantly reduces assembly time while ensuring reliable electrical insulation.
3Ease of manufacture
If brush component is fixed on support bracket separately, then installation is facilitated, but components are divided into multiple portions requiring sequential assembly
Solution Approach 1:
The patent merges the brush component mounting with the overall motor assembly process by providing a support bracket that is integrated with or directly attachable to the motor housing. The brush component is fixed on this support bracket in a manner that allows it to be installed simultaneously with other motor components through the same housing structure, reducing the number of separate assembly steps while maintaining ease of installation.
Data Source
AI summary
The present disclosure discloses an electric winch which comprises a motor having a motor housing, a first terminal, a second terminal and a third terminal, and an insulating cover plate having a mounting hole, a first inner bore column and a second inner bore column. A first through hole, a second through hole and a third through hole are provided on an outer edge of the motor housing. The embodiment allows pre-mounting of the terminals on the insulating cover plate before they are fixed to the motor housing and provides higher efficiency in the assembly process.