BLDC Fan Motor Y-Winding Layout for Compact Inverter Cooling
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Solution Overview
Problem
The existing brushless direct current (BLDC) motors with integrated inverter units face challenges in miniaturization due to increased size from cylindrical capacitors, complex winding processes, and high probability of incorrect connections in parallel coil configurations, leading to reliability issues and heat dissipation problems.
Innovation Solution
The motor design winds coils in a three-phase Y connection method on a per-strand basis, with overlapping primary and secondary windings around tooth portions, using a neutral point terminal with dual plates and grooves for stable electrical connections, and positions heat-generating elements close to the impeller for airflow cooling, reducing the overall size and interference with other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the coil diameter is made thicker to increase current capacity, then motor performance is improved, but winding becomes difficult and connector/harness size must be enlarged
Solution Approach 1:
The coil is divided into multiple strands instead of using a single thick coil. This segmentation allows easier winding while maintaining the required current capacity through parallel connection of multiple thinner strands, resolving the contradiction between power and ease of manufacture.
2Ease of manufacture
If the number of slots is increased to facilitate coil winding, then winding becomes easier, but stator size increases and structure becomes complicated
Solution Approach 1:
The coil is segmented into multiple strands that can be wound around existing slots and connected in parallel at the neutral point. This approach maintains the original stator slot structure while enabling easier winding through the use of multiple flexible strands, avoiding both increased slot count and structural complexity.
3Power
If six coils are connected in parallel at the neutral point in a three-phase multi-pole motor, then current capacity is increased, but the probability of incorrect connection increases and product reliability is degraded
Solution Approach 1:
Multiple coil strands are merged into a single integrated neutral point terminal structure. This merging reduces the number of separate connection points from six to one unified terminal, significantly reducing the probability of incorrect connections and improving reliability while maintaining current capacity.
4Power
If at least six coils are connected at the neutral point, then current capacity is increased, but the size of the neutral point terminal increases and component design becomes difficult
Solution Approach 1:
The neutral point terminal is designed as a single integrated component that combines multiple connection functions. This merging allows the terminal to handle parallel coil connections without requiring a large physical size, as the unified structure efficiently manages current paths while minimizing space occupation.
5Adaptability or versatility
If cylindrical capacitors are provided in the inverter unit, then inverter functionality is achieved, but the overall height of the motor increases
Solution Approach 1:
The inverter components including capacitors are arranged in a planar configuration on the PCB rather than extending vertically. This dimensional change from vertical stacking to horizontal layout maintains inverter functionality while minimizing the height dimension of the motor.
6Temperature
If heat dissipation structures such as radiating fins are provided for inverter components, then heat removal is improved, but the structure becomes complicated and area increases
Solution Approach 1:
The motor's own operational airflow serves as the cooling mechanism for inverter components. The airflow generated during motor operation naturally passes through the inverter area, providing self-service cooling without requiring additional heat dissipation structures like radiating fins, thus maintaining structural simplicity.
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 approach simplifies the winding process, miniaturizes the neutral point terminal, improves motor performance, and effectively cools heat-generating elements without separate cooling devices, enhancing reliability and efficiency while reducing the motor's size and complexity.
Implementation Method 1
heat generating elements, that is, a MOSFET element or a capacitor, which face the impeller 70. The heat generating elements are cooled by the airflow generated by the impeller 70
Implementation Method 2
a coil which is wound in double around one tooth portion 23a of the plurality of tooth portions 23, passes by the neutral point terminal 30, and is then wound in double around another tooth portion 23b
Data Source
Figure 1
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Figure 3
AI summary
A motor and a home appliance having the same are proposed. The motor includes a rotor assembly (50) rotating about a rotation shaft (52); and a stator assembly (20) accommodating the rotor assembly (50). The stator assembly (20) include a stator core (21) including a plurality of tooth portions (23a to 23c) constituting three phases of U, V, and W; a coil wound around the tooth portions (23a to 23c) in a type of a three-phase Y connection of U, V, and W; a neutral point terminal (30) forming a neutral point of the three-phase Y connection; a plurality of power terminals (40a to 40c) forming U, V, and W phases in the three-phase Y connection. The coil is primarily wound around each tooth portion(23a to 23c), passes by a power terminal (40a to 40c), and then secondarily wound around each tooth portion (23a to 23c) in an overlapping manner.