Brushless Motor Phase Wire Adapter for PCB Alignment
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Solution Overview
Problem
Existing drive devices for motor vehicles, particularly those with brushless electric motors, face challenges in efficiently and reliably connecting phase connection wires to the stator winding, requiring manual bundling and precise alignment, which is cumbersome and prone to errors.
Innovation Solution
A drive device with a connection adapter that radially orients phase connection wires, allowing them to be automatically aligned with printed circuit board connections, using a plastic adapter with features like mounting dowels and crimping lugs for secure fixation, and a clamping ring for precise positioning, enabling automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual bundling and fixing of phase connection wires is used, then precise positioning can be achieved, but assembly complexity and time increase
Solution Approach 1:
A connection adapter is introduced as an intermediary component between the stator winding and the printed circuit board. The adapter features a connection grid with connection points that automatically align with the PCB connection points, eliminating the need for manual wire positioning while ensuring precise electrical connections.
Solution Approach 2:
The phase connection wires are pre-positioned and pre-connected to the stator winding terminals before assembly. The connection adapter is designed with pre-defined connection points that correspond to the PCB layout, allowing automated assembly without manual intervention during the final assembly process.
2Manufacturing precision
If two axes or planes of movement are required for circuit board assembly, then precise positioning can be achieved, but productivity decreases
Solution Approach 1:
The connection adapter transforms the positioning requirement from two-dimensional (requiring alignment in two axes or planes) to one-dimensional. The adapter's connection grid is designed to automatically align with the PCB connection points along a single axis, simplifying the assembly process and enabling automated high-speed assembly.
3Reliability
If stator-rotor assembly requires precise alignment before insertion, then reliable mounting can be achieved, but assembly time increases
Solution Approach 1:
The connection adapter is designed to self-align with the printed circuit board during assembly. The adapter's geometry and connection grid configuration enable automatic positioning without requiring external alignment tools or manual adjustment, ensuring reliable mounting while minimizing assembly time.
Data Source
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AI summary
The invention relates to a drive device (1), in particular a window-raising drive of a motor vehicle, comprising: a brushless electric motor (4) having a rotor (13) with a rotor shaft (16) coupled to said rotor, and having a stator (12) which comprises a sleeve-like or hollow-cylindrical stator support (29) and a rotating field winding or stator winding (14) having a number of phase connection wires (26); a gear mechanism housing (2) having an electronics compartment (23) with a printed circuit board (21) which can be inserted or is accommodated in said compartment and has connection points (27) for the phase connection wires (26), and having a housing shaft (25) which is coaxial with respect to the axis of rotation (D) of the rotor shaft (16) and in which the stator (12) is accommodated or can be inserted together with the stator support (29) and the rotor (13) is accommodated or can be inserted together with the rotor shaft (16); and a connection adapter (30) in which the phase connection wires (26) are oriented radially and are accommodated in a connection grid which is adapted to the connection points (27) of the printed circuit board (21).