BLDC Motor Internal PCB Connection for Compact Dual-Sensor Control
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Solution Overview
Problem
The existing electric motors for vehicle applications, such as those used in gearboxes or transmission devices, require complex wiring and external connections for multiple control boards and sensors, which increases space requirements and vulnerability to vibrations.
Innovation Solution
An electric motor design that incorporates a connection member within the housing to connect two control boards internally, reducing the need for external connections and allowing for a single interface to a central control unit, thereby minimizing space usage and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two separate control boards are used for determining parameters of rotor shaft and output shaft, then measurement capability is improved, but device complexity and wiring complexity increase
Solution Approach 1:
The patent combines two separate control boards into a single integrated control board that houses both determination devices (first and second sensors). This merging eliminates the need for separate wiring connections for each control board, reducing wiring complexity while maintaining the capability to determine both rotor shaft and output shaft parameters simultaneously.
Solution Approach 2:
The single control board is designed to perform multiple functions by integrating both determination devices within it. This universal control board can determine parameters of both the rotor shaft and output shaft, eliminating the need for separate specialized control boards and reducing overall system complexity.
2Adaptability or versatility
If control boards are connected externally outside the housing, then connection flexibility is improved, but build space requirements increase
Solution Approach 1:
The patent nests both determination devices and the control board within the existing housing of the electric motor. The control board is integrated into the housing structure, and the determination devices are arranged within the available internal space, eliminating the need for external connections and reducing the overall build space requirements.
Solution Approach 2:
The patent utilizes the internal three-dimensional space within the housing by arranging the control board and determination devices in different axial positions and spatial configurations. This efficient use of internal volume allows all components to be contained within the housing without increasing the external footprint of the motor.
3Ease of operation
If multiple individual connection ports are provided for control boards, then connection accessibility is improved, but structural integrity decreases
Solution Approach 1:
The patent merges multiple connection functions into a single connection port on the housing. This single port provides access to both determination devices through the integrated control board, maintaining connection accessibility while eliminating multiple openings in the housing, thereby preserving structural integrity and vibration resistance.
Data Source
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AI summary
Electric motor (1), in particular BLDC-motor, comprising a control unit with a first control board (7) connected with a first determination device (9) and a second control board (8) connected with a second determination device (10), wherein at least one connection member (13, 13', 13") connects the first control board (7) and the second control board (8), wherein the connection member (13, 13', 13") is arranged in a receiving section inside a housing (6) of the electric motor (1).