Brushless Motor PCB Integration for Accurate Rotor Sensing
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Solution Overview
Problem
Existing self-controlled synchronous rotating electric machines, such as brushless motors, face challenges in simplifying the integration and maintenance of electronic control systems, particularly in tubular configurations like rolling shutter motors, where sensor-based solutions are costly and mechanically complex, and sensor-less solutions lead to vibrations and poor control during startup.
Innovation Solution
The design separates the stator/rotor assembly from the electronic control and detection components, with the control card placed parallel to the rotor axis and plugged into a flange, featuring conductive blades for electrical connections, allowing for robust and tool-free integration and maintenance, optimizing the separation of mechanical and electronic functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor-based solutions are used for rotor position detection, then rotor position detection accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent divides the electronic control system into a separate printed circuit board module that can be independently installed and removed from the motor housing. This segmentation allows the sensor-based detection system to be integrated without complicating the motor's mechanical structure, as the electronics are isolated in a separate accessible module.
Solution Approach 2:
The patent introduces a printed circuit board as an intermediary carrier that hosts the detection sensors and control electronics. This intermediary allows accurate rotor position detection through sensors while avoiding direct mechanical integration complexity, as the electronics are mounted on the accessible circuit board rather than being embedded in the motor structure.
2Measurement precision
If sensor-based solutions are used for rotor position detection, then rotor position detection accuracy is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the electronic control system into a separate printed circuit board module, the patent enables independent manufacturing and assembly of the detection system. This reduces overall manufacturing cost compared to integrating sensors directly into the motor structure, as the electronics can be produced separately and assembled in a standardized manner.
Solution Approach 2:
The printed circuit board serves as an intermediary that provides a cost-effective platform for mounting sensors and control electronics. This approach is more economical than custom-integrating sensors into the motor housing, as it allows use of standardized electronic components and assembly processes.
3Device complexity
If sensor-less solutions are used for control, then device complexity is reduced, but motor control performance deteriorates during startup
Solution Approach 1:
The patent segments the control system into a separate electronic module that can implement sophisticated sensor-based control algorithms. This segmentation allows the use of accurate sensor feedback for reliable startup control without increasing the mechanical complexity of the motor itself, as the enhanced control capability is provided by the separate electronics.
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
This configuration enhances the reliability and durability of electrical connections, simplifies assembly and maintenance, and ensures accurate rotor position detection, improving motor control and reducing startup vibrations.
Implementation Method 1
means for detecting the position of the rotor... a magnetic field detection sensor placed radially at the level of and in front of the end of the ring of permanent magnets of the rotor
Implementation Method 2
means for generating a three-phase current for creating rotating magnetic fields in the stator... Transform Electrical Energy to Mechanical Energy
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A self-piloted synchronous rotating electric machine comprising a stator (1) with stator windings (3) having three sets of windings, a rotor (2) equipped with a ring of permanent magnets (4) on its periphery, and an axially rotating shaft (6). The stator (1) and the rotor (2) are housed in a casing (5), like a printed circuit board (30), which includes the electronic control means with the means for generating a three-phase current and the means for detecting the position of the rotor (2) (31). The board (30) is arranged parallel to the axis of rotation of the rotor (2) outside the casing (5), but inserted into a slot (21) in an end flange (9) closing the casing (5). The plugged portion of the card (30) includes the conductive tracks (32) for connecting the stator windings and a magnetic field detection sensor (31) with respect to the rotor (2).