Brushless DC Motor PCB with Integrated Sensor Wings
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Solution Overview
Problem
Existing printed circuit boards for brushless DC motors using through-hole technology are cumbersome, requiring manual assembly, time-consuming soldering processes, and result in reduced quality and structural stability, especially in space-constrained applications like the automotive industry.
Innovation Solution
The use of surface-mounting technology with sensors attached to the inside of a recess via solderable pads on the printed circuit board, allowing for direct soldering and eliminating the need for separate supports and manual connection of power supply components, enabling quicker assembly and improved structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If through-hole technology is used to attach Hall sensors to the circuit board, then the sensors can be securely mounted, but the assembly process becomes time-consuming and requires manual soldering
Solution Approach 1:
The circuit board is segmented into a main board and separate support wings that protrude into the recess. The Hall sensors are mounted on these wings rather than directly on the main board, allowing automated surface-mount placement while the wings provide mechanical support and positioning during assembly.
Solution Approach 2:
The support wings are pre-formed as integral parts of the circuit board structure, protruding into the recess before assembly. This preliminary structural preparation enables automated pick-and-place machines to accurately position and solder the Hall sensors without requiring manual intervention for positioning or support structures.
2Manufacturing precision
If through-hole technology with separate plastic supports is used, then sensor positioning is stabilized, but the device complexity increases
Solution Approach 1:
The support function and the circuit board structure are merged into a single integrated component. The support wings are formed as integral extensions of the circuit board itself, eliminating the need for separate plastic supports and reducing the number of discrete parts while maintaining precise sensor positioning capability.
Solution Approach 2:
The support wings serve multiple functions: they provide mechanical support for the Hall sensors, define the positioning geometry for automated placement, and act as the soldering substrate. This multi-functionality replaces multiple separate components (supports, positioning fixtures, solder pads) with a single integrated structure.
3Manufacturing precision
If manual assembly and soldering processes are used, then precise component placement is achieved, but production costs increase
Solution Approach 1:
The circuit board structure with its integrated support wings automatically provides the positioning and support functions that would otherwise require separate fixtures and manual operations. The design itself enables automated machinery to perform placement and soldering without human intervention, making the manufacturing process self-sufficient and highly automatable.
4Reliability
If the Hall sensors are mounted in TO92 housings with 1.5 mm thickness, then the sensors are protected, but the overmoulding thickness becomes insufficient in space-constrained applications
Solution Approach 1:
Instead of reducing sensor housing thickness, the solution changes the spatial arrangement by mounting sensors on protruding wings that extend into the recess. This dimensional reconfiguration allows the main circuit board to maintain sufficient thickness for overmoulding while the sensors are positioned in the recess space, effectively utilizing three-dimensional space rather than compromising linear dimensions.
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 and cost-reduces the production of high-quality printed circuit boards by eliminating manual assembly and soldering complexities, enhancing structural stability and quality through secure encapsulation and efficient component placement.
Implementation Method 1
the circuit board having a power supply for the power supply of the sensors and the DC motor
Implementation Method 2
the sensors are attached to the inside of the recess in a vertical position to the circuit board bent wings of the circuit board by means of solderable pads
Data Source
Figure 1~2
Figure 3
AI summary
The board (1) has hall sensors (4) for detection of a position of a rotor of a brushless direct current motor, where the rotor is guided in an opening (10) of the board. The sensors are arranged in circumferential area of the opening. A power supply line is provided for supplying power to the sensors and the motor. The sensors are attached to an airfoil (3) that is bent from interior of the opening in a position perpendicular to the board by solderable contact surfaces.