Brushless DC Motor Plate Module for Height Reduction
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Solution Overview
Problem
Conventional brushless DC motor designs, particularly in electric power steering systems, face challenges in miniaturization and manufacturing efficiency due to the complexity of busbar connections, which increase motor height and require lengthy processing times.
Innovation Solution
A motor design that replaces the traditional busbar with a plate module stacked with multiple plates, each with specific through holes and terminal holes, allowing for efficient electric power supply to the coil, reducing motor height and simplifying the assembly process by using a copper conductive layer and soldering connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar is used to connect the coil terminal, then electrical connection is achieved, but the motor height increases
Solution Approach 1:
The patent transitions from a conventional busbar structure extending vertically to a plate module structure arranged horizontally. The plate module consists of multiple plates stacked in layers, with coil terminals passing through holes in the plates and being soldered to copper conductive layers on the plate surfaces. This dimensional reorganization reduces the vertical height requirement while maintaining electrical connectivity through the horizontal plate assembly.
Solution Approach 2:
The busbar is segmented into multiple individual plates forming a plate module. Instead of using a single monolithic busbar, the patent divides the electrical connection function across multiple plates, each with through-holes and copper conductive layers. This segmentation allows for a more compact arrangement that reduces overall motor height while distributing the electrical connection function across the stacked plate structure.
2Reliability
If a busbar is used to connect the coil terminal, then electrical connection is achieved, but manufacturing processing time increases
Solution Approach 1:
The plate module is pre-assembled with through-holes and copper conductive layers prepared in advance. The coil terminals are inserted through the pre-drilled holes and soldered to the pre-positioned copper layers on the plate surfaces. This preliminary preparation of the plate structure simplifies the manufacturing process compared to forming and assembling a complex busbar, reducing overall processing time.
Solution Approach 2:
The patent replaces the mechanical busbar formation and assembly process with a soldering-based connection system. Instead of mechanically assembling busbar components, the coil terminals are soldered directly to copper conductive layers on the plate surfaces. This substitution of mechanical assembly with soldering simplifies the manufacturing process and reduces processing time.
3Reliability
If a busbar structure is used, then electrical power supply is achieved, but device complexity increases
Solution Approach 1:
The patent extracts the essential electrical connection function from the complex busbar structure and implements it through a simplified plate module. By removing the unnecessary complexity of busbar formation and assembly, and retaining only the essential function of electrical connection through plates with through-holes and copper layers, the device complexity is reduced while maintaining power supply capability.
Solution Approach 2:
The plate module serves multiple functions: it provides structural support, enables electrical connection through through-holes, and offers mounting surfaces for copper conductive layers. This multi-functionality consolidates what would otherwise require separate components into a single integrated plate structure, reducing overall device complexity.
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 design achieves a more compact motor form and enhances assembly productivity by eliminating the need for complex busbar connections, reducing manufacturing time and motor height while maintaining effective electrical connections.
Implementation Method 1
a copper conductive layer and soldering connections
Implementation Method 2
a copper conductive layer and soldering connections
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A motor is provided, the motor including a motor housing (10), a stator (20) mounted inside the motor housing and including a stator core and a coil wound on the stator core, a rotor (30) rotatably installed at a center of the stator, and a plate module (100) stacked with a plurality of plates, and coupled to the stator (20) and to an upper surface of a rotor (30) to supply an electric power to the coil.