Brushless Motor Winding Layout to Avoid Screw-Wire Interference
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Solution Overview
Problem
The existing brushless motor design faces challenges where crossover wires interfere with screws when a fan is fixed to the top wall of the rotor housing, leading to potential size increases and cost increments due to the need for wider gaps or complex terminal connections.
Innovation Solution
The brushless motor design rearranges crossover wires to be entirely on the opposite side of the annular section from the top wall, allowing screws and wires to coexist without interference, and consolidates terminal portions in specific slots to simplify connections and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crossover wires are arranged on the top wall side of the rotor housing, then terminal connections can be simplified, but screws and crossover wires interfere with each other when a fan is fixed
Solution Approach 1:
The patent resolves the interference problem by moving crossover wires from the top wall side to the bottom wall side of the rotor housing, utilizing the axial dimension to separate the spatial locations of screws and crossover wires. This dimensional relocation eliminates interference while preserving terminal connection simplicity.
2Object-affected harmful factors
If a gap is widened between the top wall and crossover wires to avoid interference, then screw and wire interference is suppressed, but the axial direction size of the motor increases
Solution Approach 1:
Instead of increasing the gap distance on the top wall side to avoid interference, the patent inverts the approach by relocating the crossover wires to the bottom wall side. This inversion of spatial arrangement eliminates interference without requiring increased axial dimensions.
3Ease of manufacture
If terminal portions are consolidated on one side of the central axis, then terminal structure is simplified and cost is reduced, but crossover wire routing becomes more complex
Solution Approach 1:
The patent applies local quality by consolidating terminal portions to the bottom wall side while routing crossover wires through the annular section to the top wall side. This creates distinct functional zones: terminal consolidation area for manufacturing simplicity and wire routing area for electrical connectivity, resolving the contradiction between structural simplicity and routing complexity.
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 design prevents interference between screws and crossover wires, maintains motor size, and simplifies terminal connections, thereby suppressing axial size increases and reducing costs.
Implementation Method 1
a stator that includes a stator core having an annular section and plural teeth formed in a radial pattern around an outer side of the annular section, the stator also including plural windings wound around the plural teeth, a rotor that includes a rotor housing having a top wall disposed on one axial direction side of the stator and a peripheral wall surrounding the stator, the rotor also including plural magnets fixed to the peripheral wall
Data Source
AI summary
Plural windings are wound around plural teeth in sequence such that crossover wires formed in the plural windings are all arranged on another axial direction side of an annular section of a stator core. When this is performed, the plural windings are wound around the plural teeth in sequence such that terminal portions of the plural windings are placed in a fifth slot, a sixth slot, an eighth slot, and a ninth slot.