Brushless Motor Control Device Axial Compactness
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Solution Overview
Problem
Existing electric motors and pumps face challenges in downsizing, waterproofing, and improving workability during resistance welding, particularly due to the layout of components and the use of costly special-shaped electrode bars, which affects manufacturing costs and efficiency.
Innovation Solution
The design includes a motor unit with a stator and rotor inside a motor case, a control device integrated to the motor case, a bus bar unit with a connector unit on the base unit, and a sealing member around the connector unit to prevent water infiltration, allowing for a more compact and waterproof electric motor and pump configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the driver unit and control unit are arranged on the same side of the base unit, then the layout is simpler, but the axial length increases and compactness deteriorates
Solution Approach 1:
The control device is segmented into a driver unit and a control unit, which are arranged on opposite sides of the base unit. This segmentation allows each unit to be positioned independently, reducing the axial length while maintaining layout simplicity through systematic arrangement.
Solution Approach 2:
Instead of arranging components only in the axial direction, the patent utilizes the radial dimension by positioning the driver unit and control unit on opposite sides of the base unit. This dimensional transition reduces axial length while maintaining compactness.
2Reliability
If a special-shaped electrode bar is used for resistance welding, then welding reliability improves, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive special-shaped electrode bars with standard round electrode bars. Although standard bars may require slightly more careful positioning, they are significantly cheaper and can be easily replaced, reducing manufacturing costs while maintaining adequate welding reliability.
Solution Approach 2:
The patent changes the electrode bar parameter from a special shape to a standard round shape. This parameter change simplifies procurement and reduces cost, while the welding process parameters are adjusted to compensate for the shape change, maintaining reliability.
3Ease of manufacture
If the connector unit is positioned without a sealing member, then assembly is simpler, but waterproofing performance deteriorates
Solution Approach 1:
A sealing member is introduced as an intermediary component between the connector unit and the housing. This sealing member effectively blocks water infiltration while adding minimal complexity to the assembly process, as it can be installed in a single step during assembly.
4Volume of moving object
If the motor case and pump case are integrated, then overall size is reduced, but manufacturing complexity increases
Solution Approach 1:
The motor case and pump case are merged into a single integrated housing structure. This merging reduces the overall volume and eliminates the need for separate manufacturing and assembly of two cases, actually simplifying the manufacturing process while achieving compactness.
Data Source
AI summary
This electric motor includes: a brushless motor (20); and a control device (50) that is coupled integrally to an end of a motor case (11) in an axial direction. The control device (50) includes: a bus bar unit main body (53) that has a base unit (54) with a plurality of bus bars wired thereinside and has a connector unit (58) provided integrally on the base unit (54) and led out to an outside of a housing (10); a motor drive unit (66) that drives the brushless motor (20); and a motor control unit (71) that controls the motor drive unit (66). The motor drive unit (66) is attached to a first main surface (51) of the base unit (54) while the motor control unit (71) is attached to a second main surface (52) of the base unit (54).