Modular Wire Feeder Motor Mount with Insulating Plates
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Solution Overview
Problem
Existing wire feeders for welding require complex isolation and connection between the motor and base assembly, making modular construction difficult due to unique hole mounting patterns for different motor types and the need for electrical insulation, which increases manufacturing costs and complexity.
Innovation Solution
A modular wire feeder design featuring a base assembly with an insulating mounting plate and cap, allowing different motor types with the same shaft and key size to be mounted, providing electrical isolation between the motor and drive assembly using non-conductive materials and rotating connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical insulation is provided between motor and base assembly using traditional metal fasteners and isolation components, then electrical isolation is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces an intermediate mounting plate made of electrically insulating material positioned between the motor mounting plate and the base assembly. This intermediate plate serves as a mediator that provides electrical isolation while simplifying the connection structure, eliminating the need for complex isolation components and metal fastener arrangements.
Solution Approach 2:
The patent changes the material parameter of the mounting plate from conductive metal to electrically insulating material. This parameter change allows the mounting plate itself to provide electrical isolation, eliminating the need for separate isolation components and simplifying the overall structure.
2Adaptability or versatility
If different hole mounting patterns are used for different motor types, then each motor type can be properly mounted, but manufacturing complexity and cost increase
Solution Approach 1:
The patent designs the mounting plate with multiple sets of mounting holes that can accommodate different motor types with different hole patterns. The mounting plate serves multiple functions by providing universal compatibility with various motor types while maintaining a single standardized design, thereby simplifying manufacturing.
3Adaptability or versatility
If modular construction is implemented to allow different motor types, then adaptability improves, but electrical isolation becomes more difficult to achieve
Solution Approach 1:
The intermediate mounting plate made of electrically insulating material acts as an intermediary component that enables modular construction with different motor types while maintaining electrical isolation. This insulating plate can be universally used with various motor types, providing both modularity and electrical isolation simultaneously.
Data Source
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AI summary
A wire feeder has a motor, mounting plate, intermediate mounting plate, and base assembly. The mounting plate has a plurality of mounting hole patterns and a shaft hole. The motor a mounting hole pattern that aligns with at least one of the plurality. One of a plurality of motor types can be mounted to the mounting plate. The mounting plate is mounted to the intermediate mounting plate, which is mounted to the base assembly. The base assembly includes a drive gear, which is connected to rotate with an insulating cap that receives a gear hub. The gear hub is connected to rotate with the motor shaft via matching keys. The insulating hub, intermediate mounting plate and mounting plate are electrically insulating, so that the base assembly is electrically isolated from the motor.