Brushless Motor Coil Layout Without Interconnecting Ring
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Solution Overview
Problem
Existing brushless electric motors for motor vehicles face issues such as increased size, manufacturing costs, weight, and efficiency losses due to interconnecting rings and welds, which also lead to potential corrosion and failure in damp environments.
Innovation Solution
A brushless electric motor design without an interconnecting ring, utilizing a DC circuit with two poles and bridge branches, semiconductor switches, and enameled wire coils, allowing for reduced electrical currents and simplified manufacturing, with a stator and rotor arrangement that minimizes mechanical contact and water condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an interconnecting ring with busbars is used to connect electrical coils, then a robust electrical connection is achieved, but the axial overall length of the motor is enlarged and manufacturing costs increase
Solution Approach 1:
The patent removes the interconnecting ring component entirely from the motor design. Instead of using busbars on an interconnecting ring to connect electrical coils, the invention uses individual electrical connections directly from each coil to the electronic system, eliminating the need for the interconnecting ring and thus reducing the axial overall length while maintaining electrical connection functionality
Solution Approach 2:
The patent integrates the electrical connection function directly into the coil assembly and electronic system interface. By combining the connection terminals and electrical pathways into a more compact arrangement that eliminates the separate interconnecting ring component, the design achieves robust electrical connections without the additional axial length that a separate interconnecting structure would require
2Reliability
If an interconnecting ring with busbars is used to connect electrical coils, then a robust electrical connection is achieved, but manufacturing costs and weight increase
Solution Approach 1:
The patent eliminates the interconnecting ring component, which removes the need for specialized welding machines and complex assembly processes. This simplification directly reduces manufacturing costs while maintaining electrical connection robustness through alternative connection methods that are more easily manufactured
Solution Approach 2:
The patent replaces the expensive, complex interconnecting ring assembly with simpler, more cost-effective individual electrical connections. By using straightforward connection methods without requiring precision welding equipment and specialized assembly, the invention achieves reliable electrical connections at lower manufacturing cost
3Weight of stationary object
If busbars with reduced cross-section are used, then manufacturing costs and weight are reduced, but excessive heating occurs in the region of the interconnecting ring
Solution Approach 1:
By removing the interconnecting ring entirely, the patent eliminates the heating problem that would occur in that region. The design uses individual electrical connections that do not concentrate current in a single interconnecting structure, thereby avoiding excessive heating while still using reduced cross-section conductors to reduce weight and cost
4Reliability
If welds are made in inaccessible positions to connect coils to the interconnecting ring, then a robust electrical connection is achieved, but specialized machinery is needed which increases manufacturing costs
Solution Approach 1:
The patent removes the interconnecting ring that would require inaccessible welds. By using direct electrical connections from coils to the electronic system with accessible terminals, the invention achieves robust electrical connections without requiring specialized welding machinery or complex assembly procedures
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
The design reduces overall size, manufacturing costs, weight, and electrical losses, improving efficiency and reliability while preventing corrosion and simplifying assembly.
Implementation Method 1
The brushless electric motor comprises a number of electrical coils, which are distributed to multiple phases
Data Source
AI summary
A brushless electric motor for a motor vehicle, including a stator, which has a number of electrical coils, which are distributed to multiple phases, and has an electronic system, which has a DC circuit with two electrical poles. Multiple bridge branches are connected between the poles. Two bridge branches in each case form a bridge pair, and each phase is connected in each case between the bridge branches of one of the bridge pairs. The invention also relates to a motor scooter including a main drive.