Brushless Motor PCB Phase Connection Layout for Easier Assembly
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Solution Overview
Problem
Existing drive devices with brushless electric motors face complex and component-intensive connection challenges for phase connections, particularly in harsh environments like motor vehicles, where manual soldering or plug connections are required for three-phase windings.
Innovation Solution
A drive device design featuring a brushless electric motor with pre-bent phase connections that automatically align with corresponding receptacles on a circuit board, allowing for precise and fail-safe plug-in connections, which can then be selectively soldered, reducing complexity and component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering or plug connections are used for phase connections, then electrical connection is achieved, but device complexity and component count increase
Solution Approach 1:
The patent merges the phase connection terminals and connection receptacles into a single integrated circuit board structure. The connection receptacles are directly formed on the circuit board, eliminating the need for separate plug connectors. This integration reduces the number of components while maintaining reliable electrical connections between the motor windings and control electronics.
Solution Approach 2:
The circuit board serves multiple functions: it provides electrical connection terminals for power supply, houses the control electronics for the brushless motor, and integrates the connection receptacles for phase wiring. This multi-functionality reduces overall device complexity by consolidating what would otherwise require separate components.
2Reliability
If plug connections with clamping and fork contacts are used, then electrical connection is achieved, but space requirements increase
Solution Approach 1:
The patent combines the clamping contact and fork contact functions into a single integrated connection receptacle structure on the circuit board. The receptacle directly receives and secures the phase connection terminals without requiring separate clamping mechanisms or fork-shaped contacts, thereby reducing the space required for connections.
3Reliability
If manual soldering is used for phase connections, then electrical connection is achieved, but manufacturing time and complexity increase
Solution Approach 1:
The circuit board is pre-equipped with connection receptacles that are integrally formed during board manufacturing. This preliminary preparation eliminates the need for manual soldering operations during final assembly, as the receptacles are already in place to receive and secure the phase connection terminals through simple plug-in operations.
Solution Approach 2:
The patent replaces the manual soldering process with a mechanical plug-in connection system. The connection receptacles are designed to mechanically secure the phase terminals without requiring thermal processing or adhesive bonding, thereby simplifying the manufacturing process and reducing assembly complexity.
Data Source
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AI summary
The invention relates to a drive device (1), having a drive housing (2) with a brushless electric motor (3) which can be installed therein and has a stator winding (21) and a rotor (20) and motor electronics (27) with a printed circuit board (26), the electric motor (3) being insertable into the drive housing (2) via a housing opening (4). A main stator body (35) has a number of stator teeth (37) which are arranged in a star shape and around which the stator winding (21) is wound, a number of phase connections (29) of the stator winding (21) being guided into an in particular radially oriented joining position (P). The printed circuit board (26) has a number of connection sockets (30) corresponding to the number of phase connections (29), said connection sockets receiving the phase connections (29) as the electric motor (3) is inserted into the drive housing (2).