Brushless Motor PCB Locating Structure for Automated Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brushless motor production processes face challenges with positional errors between the terminal on the upper insulating bobbin and the terminal connecting hole on the PCB, leading to production errors and manual soldering of lead wires, which hinders automated production.
Innovation Solution
The implementation of a locating column on the upper insulating bobbin with a tapered end and a corresponding locating hole on the PCB, along with optimized design features like wire-through slots and notches, ensures accurate positioning and reduces errors, enabling automated assembly and simplifying the structure to facilitate high-yield production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the PCB is secured on the casing first and then assembled with the upper insulating bobbin, then the assembly process can be automated, but mounting alignment errors between the terminal and terminal connecting hole occur
Solution Approach 1:
A locating structure consisting of a locating column on the upper insulating bobbin and a locating hole on the PCB serves as an intermediary positioning mechanism. This mediator ensures precise alignment between the terminal and terminal connecting hole during automated assembly, eliminating mounting alignment errors while maintaining automation capability.
Solution Approach 2:
The locating column and locating hole are pre-positioned on the upper insulating bobbin and PCB respectively before the actual assembly process. This preliminary positioning action ensures that when the PCB is assembled with the upper insulating bobbin, the terminal and terminal connecting hole are already aligned, preventing mounting alignment errors during automated production.
2Reliability
If the lead wire is soldered to the PCB manually, then connection reliability is improved, but automated production cannot be realized
Solution Approach 1:
The manual soldering process is replaced by a mechanical pressing connection system. The terminal is designed to be pressed directly onto the lead wire, creating a reliable electrical connection through mechanical force rather than thermal soldering. This substitution enables automated production while maintaining connection reliability.
Solution Approach 2:
The terminal structure is designed to automatically secure the lead wire through its own pressing action. The terminal includes features that enable it to self-secure the lead wire during the pressing process, eliminating the need for separate soldering operations and enabling fully automated production while ensuring reliable connections.
3Productivity
If the structure is simplified to facilitate automated production, then productivity is improved, but positioning accuracy may be compromised
Solution Approach 1:
The locating column and locating hole structure serves multiple functions: it provides precise positioning for the PCB on the upper insulating bobbin, ensures alignment between the terminal and terminal connecting hole, and facilitates automated assembly. This multi-functional design achieves both simplified structure for automated production and maintained positioning accuracy.
Solution Approach 2:
The locating structure acts as a simple yet effective intermediary mechanism that provides precise positioning without adding complex assembly steps. The locating column and locating hole pair enables accurate positioning while maintaining structural simplicity, allowing both high productivity and positioning accuracy to be achieved simultaneously.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A brushless motor includes a printed circuit board having a plurality of locating holes therethrough; and an upper insulating bobbin including a plurality of locating bosses distributed along a circumference direction of an upper surface of the upper insulating bobbin. Each locating boss has a locating column projecting from a top surface thereof such that each locating column is inserted into a respective locating hole.