Brushless Motor Wire Binding Board Soldering
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Solution Overview
Problem
The existing brushless motor technologies face challenges in simplifying and optimizing the coil wire binding process, which is cumbersome and costly, and require changes to the coil structure or wiring pattern to modify the wire binding design, limiting flexibility and efficiency.
Innovation Solution
A brushless motor design where the end portion of the coil is inserted into a wire binding board with a pre-defined pattern, soldered to a land on the board, and electrically connected to a circuit board through a connecting terminal, allowing for easy pattern changes without altering the coil structure or handling of connecting wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual connecting wires are used for each coil end portion, then electrical connection is achieved, but wire binding work becomes cumbersome and manufacturing cost increases
Solution Approach 1:
Multiple individual connecting wires are merged into a single wire binding board that serves as a common electrical connection structure. The wire binding board integrates multiple connection points (lands) that simultaneously connect to multiple coil end portions, replacing the need for separate wire binding operations for each coil.
Solution Approach 2:
The wire binding board acts as an intermediary component between the coils and the circuit board. Instead of directly connecting each coil to the circuit board with individual wires, the wire binding board serves as a intermediate structure that simplifies the connection process while maintaining electrical connectivity.
2Productivity
If wire binding pattern is changed, then motor performance is optimized, but coil structure or wiring structure must be changed causing cumbersomeness
Solution Approach 1:
The wire binding board is designed as a separate, modular component with a distinct wire binding pattern that can be independently modified. This segmentation allows the pattern to be changed without affecting the coil structure itself, as the pattern is defined by the board's layout rather than the coil configuration.
Solution Approach 2:
The wire binding pattern is made changeable and adaptable through the modular wire binding board design. Different board configurations can be implemented to optimize motor performance for different applications, allowing the system to adapt to various performance requirements without redesigning the fundamental coil structure.
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 simplifies and optimizes the coil wire binding process, reducing manufacturing costs and time, while enabling straightforward changes to the wire binding pattern without modifying the coil structure or wiring, enhancing flexibility and efficiency.
Implementation Method 1
the end portion of the coil is soldered to a land of the wire binding board
Implementation Method 2
the wire binding board and the circuit board are electrically conducted to each other through a connecting terminal
Data Source
AI summary
A brushless motor includes a stator as an armature where a plurality of coils is housed and a rotor as a magnetic exciter having a permanent magnet, wherein an end portion of the coil housed in a slot of a stator stack is inserted into a wire binding board having a wire binding pattern of the coil, the end portion of the coil is soldered to a land of the wire binding board, and the wire binding board and a circuit board are electrically conducted to each other through an connecting terminal.