Brushless DC Motor Sensor Carrier Integration
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Solution Overview
Problem
Existing brushless DC motors require complex and costly manufacturing processes due to the need for precise alignment and soldering of Hall sensors, which increases design and production effort without ensuring optimal positioning.
Innovation Solution
The motor uses electrical contacts designed as insulation displacement clamps on a sensor carrier to connect control electronics to line windings, ensuring precise positioning of rotational position sensors without manual alignment or soldering, utilizing a sleeve-shaped stator housing with insulating caps and crown-shaped projections as line guides for easy and automated routing of electrical lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Hall sensors are glued to the stator with soldered electrical contacts, then the motor can detect rotor position for commutation, but the manufacturing process becomes complex and costly due to alignment and soldering efforts
Solution Approach 1:
The patent combines the Hall sensors, their electrical contacts, and positioning functions into a single integrated sensor carrier unit. This integration eliminates the need for separate alignment and soldering operations, as the entire sensor assembly can be positioned and connected as one component, directly resolving the manufacturing complexity while maintaining position detection reliability
Solution Approach 2:
The sensor carrier acts as an intermediary component that carries both the Hall sensors and their electrical contacts, and provides positioning aids that interface with the stator. This mediator structure enables precise positioning and electrical connection without requiring direct manual alignment and soldering of individual sensor components to the stator
2Manufacturing precision
If multiple separate components (printed circuit board, connection block, guides) are used for sensor positioning, then the sensors can be positioned relative to the stator, but the design and manufacture become complex with accumulating tolerances
Solution Approach 1:
The patent merges the printed circuit board, connection block, and positioning guides into a single integrated sensor carrier component. This consolidation reduces the number of parts from multiple separate components to one unified structure, eliminating tolerance accumulation between components while simplifying the overall assembly structure
Solution Approach 2:
The sensor carrier performs multiple functions simultaneously: it carries the Hall sensors, provides electrical contacts for connection to the stator windings, and includes positioning aids for precise alignment. This multi-functional design replaces the need for separate specialized components, reducing complexity while maintaining positioning precision
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 manufacturing process, reduces production costs, and ensures exact alignment of sensors, resulting in high torque and efficient motor performance.
Implementation Method 1
a rotor (7) with permanent magnets, which rotates in the alternating magnetic field of a stator (1), which changes due to commutation
Implementation Method 2
control electronics with non-contact rotary position sensors assigned to the phases of the winding system being assigned to control the spaced apart electrical line windings of the winding system provided in the stator
Data Source
Figure 1
Figure 2
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AI summary
The invention relates to a brushless DC motor having a rotor with permanent magnets which rotates in the magnetic field of a stator (1) which changes by commutation, the magnetic field of which can be generated by a winding system of circumferentially spaced conductor windings (3) applied to an insulating body (4), wherein a control electronics with non-contact rotary position sensors (5) assigned to the phases of the winding system (2) is provided for controlling the spaced electrical conductor windings of the conductor system provided in the stator (1).The DC motor according to the invention is characterized by the fact that the rotation position sensors (5) are arranged on a sensor carrier (13), that a sensor carrier (13) can be attached to at least one end face of the stator (1), and that cooperating positioning aids are provided between the at least one sensor carrier (13) and the adjacent stator end face, which define the relative position of the stator (1) with respect to the at least one sensor carrier (13) and the rotation position sensors (5) arranged on it. The DC motor according to the invention can optionally also be manufactured with minimal effort using an automated manufacturing process (see Fig. 1).