Coplanar Brushless Motor Connection Assembly Reducing Axial Height
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Solution Overview
Problem
Existing brushless electromagnetic motors with compact designs face challenges in optimizing the diameter-to-height ratio due to bulky electrical connection systems, which increase the motor's volume and hinder the production of ultra-flat 'pancake' type motors, thereby reducing available space for the rotor and stator, and compromising power and electromechanical performance.
Innovation Solution
A connection system featuring coplanar connection tracks with self-stripping ends, cut from a single conductive sheet and overmolded with insulating plastic, allowing direct and simplified connections to the coils with a limited number of parts, reducing the axial and transverse footprint, and incorporating a connector with 3 lugs for efficient electrical phase connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional connecting rings and bus bars are used for electrical connections, then reliable electrical connection is achieved, but the motor volume increases and compactness is reduced
Solution Approach 1:
The patent merges multiple separate connection components (connecting rings, bus bars, insulation elements) into a single integrated connection assembly. The conductive sheet is formed with multiple coplanar tracks that directly connect to coil terminals, eliminating the need for separate connecting rings and bus bars. This integration significantly reduces the axial height and overall volume of the connection system while maintaining reliable electrical connections.
Solution Approach 2:
The invention extracts and eliminates unnecessary intermediate components from the traditional connection system. By removing connecting rings and separate bus bars, and replacing them with direct coplanar tracks formed from a single conductive sheet, the patent achieves a more compact design. The extraction of redundant parts directly contributes to reducing motor volume while simplifying the connection system.
2Reliability
If multiple separate connection components are used, then connection reliability is improved, but the number of parts increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple connection functions into a single integrated conductive sheet structure. The coplanar tracks are formed as one piece with integrated insulation elements, replacing multiple separate components (connecting rings, bus bars, insulation sleeves). This merging reduces the number of parts while maintaining connection reliability through the robust coplanar track design that provides stable electrical connections.
Solution Approach 2:
The conductive sheet performs multiple functions simultaneously: it provides electrical connection tracks, structural support, and insulation mounting. The single integrated assembly serves as both the electrical conductor and the mechanical framework for the connection system, eliminating the need for separate structural components. This multi-functionality reduces part count while ensuring reliable connections.
3Length of stationary object
If non-coplanar tracks are used, then three-dimensional connection flexibility is achieved, but axial height increases and compactness is reduced
Solution Approach 1:
The patent transitions from traditional three-dimensional stacked connections to a two-dimensional coplanar arrangement. All connection tracks lie in the same plane, allowing direct lateral connections to coil terminals without requiring axial stacking. This dimensional change flattens the connection system, dramatically reducing axial height while simplifying the connection process through direct access to all terminals in a single plane.
4Shape
If traditional connection methods are used, then electrical connection is achieved, but the diameter-to-height ratio optimization is hindered
Solution Approach 1:
The patent reconfigures the connection system from a vertical stacked arrangement to a horizontal coplanar layout. By arranging all connection tracks in a single plane rather than stacking them axially, the design minimizes the height dimension while maintaining adequate diameter. This dimensional reconfiguration directly optimizes the diameter-to-height ratio, enabling ultra-compact pancake motor designs.
Solution Approach 2:
The integration of multiple connection functions into a single coplanar assembly reduces the overall volume occupied by the connection system. The merged structure eliminates gaps and overlaps between separate components, creating a compact unified assembly that minimizes space requirements and optimizes the motor's overall shape factor.
Data Source
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AI summary
The present invention relates to an electrical connection system and assembly for a brushless electromagnetic motor comprising a coiled stator assembly with P electric phases and X coils per phase, each coil exhibiting in proximity a body furnished with two connection slots, characterized in that it consists of a first subassembly formed of W tracks cut in a conducting sheet, said tracks forming W coplanar output tracks, W being an integer number lying between P and P+1, each of said W tracks terminating in at least one end folded back perpendicularly to the plane of said tracks, the shape of said folded back end being complementary to the shape of the connection notch, said tracks being joined by an insulating plastic material.