Brushless Motor Stator Contact Layout for Low-Height PCB Assembly
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Solution Overview
Problem
Existing brushless electric motors have a large spacing between the stator and the printed circuit board due to contacts to the electromagnets, resulting in a tall and space-consuming motor design.
Innovation Solution
Attaching contacts to the outer circumference of the stator allows for a minimal spacing between the stator and the printed circuit board, enabling the contacts to be placed deeper within the stator, reducing the motor's overall height and allowing for the use of inexpensive SMD Hall sensors for improved precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contacts are placed on the stator surface, then electrical connection is achieved, but the spacing between stator and printed circuit board increases, resulting in larger motor height
Solution Approach 1:
The patent transitions the contact placement from a planar surface arrangement to a radial arrangement on the outer circumference of the stator. By moving contacts to the cylindrical outer surface and connecting them radially outward, the design eliminates the need for axial spacing, thereby reducing motor height while maintaining reliable electrical connection.
Solution Approach 2:
Instead of having contacts extend axially outward from the stator surface (conventional approach), the patent inverts the arrangement by having contacts placed on the outer circumference and extending radially. This inversion allows the printed circuit board to be positioned closer to the stator, reducing overall motor height.
2Length of stationary object
If contacts are placed deeper in the stator, then motor height is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates sockets directly into the stator structure during manufacturing, with contact recesses pre-formed in the stator body. This preliminary preparation of mounting locations simplifies subsequent assembly, as contacts can be directly inserted into the pre-formed sockets without complex machining or additional manufacturing steps.
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 compact design reduces installation space and measurement errors, while enabling the use of cost-effective and reliable Hall sensors, and simplifies assembly with insulation-piercing contacts and sockets.
Implementation Method 1
The sensor can be a Hall sensor. These sensors are inexpensive and simple, and have proven to be reliable.
Data Source
AI summary
A brushless electric motor is provided, and includes a stator with numerous electromagnets, each of which is formed by an iron core and a wire coil. A rotor that rotates in the stator is also provided, and which has a multi-pole circular magnet or numerous permanent magnets. A printed circuit board is populated with electric and/or electronic components and a connection for electrically connecting the stator to the printed circuit board. The connection includes contacts connected to the stator, which can be electrically connected to the printed circuit board. The contacts are attached to an outer circumference of the stator.