Card Edge Connector for Motor Controller PCB Integration
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Solution Overview
Problem
Existing power equipment units, such as lawn mowers and utility loaders, face challenges in efficiently and reliably connecting electric motor windings to motor controllers, often requiring loose wires or individual connectors, which can be cumbersome and prone to errors.
Innovation Solution
The integration of a card edge connector that operatively couples the printed circuit boards of the electric motor and motor controller, facilitating a blind connection and simplifying the connection process by eliminating the need for loose wires or individual connectors for each winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If loose wires or individual connectors are used to connect motor windings to motor controller, then the connection can be flexible and easy to implement, but the reliability is reduced and the assembly process becomes cumbersome
Solution Approach 1:
The patent combines multiple individual wire connections into a single integrated printed circuit board (PCB) structure. The PCB integrates all motor winding connections and controller interfaces into one rigid connector assembly, eliminating the need for multiple loose wires and individual connectors. This merging approach improves reliability by reducing connection points while maintaining ease of assembly through the unified PCB structure.
2Adaptability or versatility
If multiple individual connectors are used for each motor winding, then the connection can be customized and adaptable, but the device complexity increases and assembly time is extended
Solution Approach 1:
The printed circuit board serves multiple functions simultaneously: it provides electrical connections for all motor windings, integrates the motor controller interface, provides structural support, and enables sealed enclosure mounting. This multi-functional PCB replaces numerous individual connectors with a single universal connection system that maintains adaptability while reducing overall device complexity.
3Ease of manufacture
If traditional wire connections are used, then the assembly process is simple and straightforward, but the power transfer efficiency is reduced and connection security is compromised
Solution Approach 1:
The patent replaces traditional mechanical wire connections with electrical traces on a printed circuit board. The PCB provides rigid, low-resistance electrical pathways that superiorly conduct power compared to flexible wires. The PCB is secured through mechanical means (mounting to the sealed enclosure) while providing optimized electrical connections, thus substituting the mechanical wire system with an integrated electro-mechanical solution that improves power transfer efficiency.
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 solution provides a robust, efficient, and simplified connection method that enhances the reliability and ease of assembly of power equipment units by ensuring secure and consistent power transfer between the motor and controller, while also sealing the components from external environments.
Implementation Method 1
The stator may be operatively coupled to the rotor to convert electrical energy into mechanical energy
Implementation Method 2
The card edge connector may be configured to operatively couple the printed circuit board of the electric motor and the printed circuit board of the motor controller
Data Source
AI summary
A power equipment apparatus may include a motor assembly including an electric motor, a motor controller, and a card edge connector. The electric motor may include a motor housing defining a cavity, a rotor disposed in the cavity, a stator disposed in the cavity, and a printed circuit board operatively coupled to the stator. The motor controller may include a controller housing, a printed circuit board disposed in the controller housing, and one or more processors operatively coupled to the printed circuit board of the motor controller. The card edge connector may be configured to operatively couple the printed circuit board of the electric motor and the printed circuit board of the motor controller.