Brushless Motor Winch Integrated Controller
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Solution Overview
Problem
Conventional winches powered by brushed motors face issues with carbon brush wear, bulky size, unstable relay contacts, and high energy consumption, while brushless motor systems have low integration levels, leading to inefficiencies and safety hazards.
Innovation Solution
A winch integrated with a permanent magnet brushless motor and a controller, where the brushless motor assembly includes a stator, rotor, and controller integrated within a compact structure, reducing energy consumption and enhancing reliability by eliminating long wire connections and control box assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brushed motor is used to power the winch, then the structure is simple and cost is low, but the carbon brush easily gets frayed, relay contacts are unstable, and energy consumption is high
Solution Approach 1:
The patent replaces the brushed motor's mechanical commutator and carbon brush system with an electronic commutation system using Hall sensors and transistors. This substitution eliminates the mechanical wear components (carbon brushes) while achieving the same function of commutating the motor current, thereby improving reliability without significantly increasing overall system complexity.
Solution Approach 2:
The patent integrates the controller directly into the motor assembly, merging the previously separate motor and controller components into a single integrated unit. This consolidation reduces the number of external connections and relay contacts, improving reliability while managing system complexity through functional integration.
2Reliability
If a control box assembly with relay is used, then the control function is achieved, but the size becomes bulky and relay contacts are unstable
Solution Approach 1:
The patent merges the controller into the motor assembly, eliminating the need for a separate control box assembly. The controller components (Hall sensors, transistors, resistors, capacitors) are mounted directly on the motor's circuit board, reducing the overall volume while maintaining control functionality and improving reliability by removing external relay contacts.
Solution Approach 2:
The patent replaces the mechanical relay contact system with an electronic switching system using transistors. This substitution eliminates the physical relay contacts that are prone to adhesion and loose contact, achieving more reliable switching without requiring a bulky control box assembly.
3Loss of energy
If long wire connections are used between motor and relay, then the control function is achieved, but electrical energy loss and voltage drop occur
Solution Approach 1:
The patent merges the controller with the motor assembly, placing the switching components directly adjacent to the motor windings. This integration dramatically shortens the wire connections between the control elements and the motor, reducing electrical energy loss and voltage drop while simplifying the overall wiring structure.
4Productivity
If brushless motor and controller are separately designed, then the design flexibility is maintained, but the integration level is low and efficiency is reduced
Solution Approach 1:
The patent merges the brushless motor and controller into a single integrated assembly. The controller components are mounted directly on the motor's circuit board, and the Hall sensors are positioned within the motor structure. This integration improves system efficiency by reducing connection losses and simplifying the overall structure, while the modular design maintains sufficient design flexibility.
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
The integrated design results in a more efficient, compact, and reliable winch with reduced energy consumption and manufacturing costs, while ensuring stable operation and safety by minimizing electrical energy loss and improving mounting flexibility.
Implementation Method 1
a rotor and a rotating shaft fixed in a rotor center are provided in the stator, one end of the rotating shaft is fixedly connected with a magnet mount, and a cylinder magnet is mounted in the magnet mount
Data Source
AI summary
A winch integrated with a permanent magnet brushless motor and a controller includes a brushless motor and a controller. The brushless motor includes a stator having a wire coil, and a motor bracket. The stator is fixedly provided in the motor bracket. A rotor and a rotating shaft fixed in a rotor center are provided inside the stator. The rotating shaft is rotatably connected to the motor bracket, one end of the rotating shaft is fixedly connected with a magnet mount, and a cylinder magnet is mounted in the magnet mount. The controller includes a control circuit board fixed to one end of the motor bracket proximal to the cylinder magnet. A sensor chip for angle sensing in conjunction with the cylinder magnet is provided on the control circuit board.