Brushless Motor Circuit Board Mounting via Notch-Aligned Holder
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Solution Overview
Problem
Existing brushless motors with built-in position sensors and circuit boards face challenges in workability due to difficult manual insertion of the circuit board into the motor housing, leading to misalignment and reduced efficiency, noise, and increased dispersion in motor characteristics.
Innovation Solution
A brushless motor design featuring a board holder with a lead-wire holder aligned with the motor housing notch, allowing easy insertion and accurate positioning of the circuit board, along with a method that includes assembling the board assembled unit with the lead-wire holder aligned with the notch, ensuring the circuit board is mounted correctly and efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the circuit board is manually inserted into the motor housing, then the circuit board can be mounted inside the housing, but the workability is lowered due to difficulty in placement
Solution Approach 1:
The circuit board is preliminarily fixed to the positioning section using a positioning pin before final assembly. This preliminary positioning action ensures the board is correctly aligned and makes the subsequent insertion process much easier and more reliable.
Solution Approach 2:
A positioning pin is introduced as an intermediary tool to facilitate the insertion of the circuit board. The positioning pin engages with the positioning hole on the circuit board and the corresponding positioning section in the housing, acting as a mediator that guides and secures the board during assembly.
2Manufacturing precision
If the circuit board is accurately mounted to prevent misalignment, then positioning accuracy is improved, but the manufacturing complexity increases
Solution Approach 1:
The circuit board has a positioning hole built into its structure that automatically engages with the positioning section in the housing. This self-positioning feature ensures accurate alignment without requiring complex external fixtures or manual adjustment procedures during manufacturing.
Solution Approach 2:
The positioning pin is pre-installed on the positioning section before the circuit board is mounted. This preliminary preparation ensures that when the board is inserted, it automatically aligns with the correct position through the positioning hole, simplifying the mounting process while maintaining high precision.
Data Source
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AI summary
A brushless motor includes a stator having a stator core, a rotor, a circuit board, a board holder for holding the circuit board, a motor housing having a notch at an opening, and a housing cover. The motor housing accommodates the stator, the rotor, and the board holder to which the circuit board is mounted, and the motor housing is sealed with the housing cover. The board holder includes a board mount section, a lead-wire holder for holding lead-wires. The lead-wire holder is placed at the notch of the motor housing. The lead-wires extend from the circuit board mounted to the board mount section to the outside of the motor housing via the lead-wire holder.