Coreless Coil Stator Module Automated Assembly
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Solution Overview
Problem
Conventional micro fan production with manual assembly of stators on silicon steel elements leads to welding defects, especially in smaller sizes, resulting in poor electrical performance.
Innovation Solution
A brushless DC motor fan design featuring a coreless coil and lead frame with a stator module, where the lead frame includes six pins electrically connected to the coreless coil, and a manufacturing method that automates the assembly process, including packaging the coreless coil and lead frame to form a stator module, which is then connected to a circuit board via these pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual assembly and welding is used to produce micro fan stators, then flexibility in assembly is maintained, but welding defects occur leading to poor electrical performance
Solution Approach 1:
The patent replaces manual mechanical assembly and welding operations with an automated pick-and-place machine that uses suction cups to pick up stators and precisely place them onto the PCB board. This substitution eliminates human error and welding defects, ensuring consistent electrical performance while maintaining manufacturing efficiency.
2Manufacturing precision
If automated pick-and-place assembly is used, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The automated assembly system uses a multi-functional pick-and-place machine that combines suction cup-based stator pickup, precision positioning, and automated placement capabilities in a single device. This universal equipment handles multiple assembly tasks simultaneously, achieving high manufacturing precision without proportionally increasing overall system complexity.
3Productivity
If manual welding is used for stator assembly, then equipment simplicity is maintained, but productivity is reduced due to labor-intensive processes
Solution Approach 1:
The system performs preliminary actions by using suction cups to securely grasp stators before placement, and by pre-positioning them accurately on the PCB board. This preliminary automated handling eliminates the need for subsequent manual welding operations, significantly increasing assembly speed while managing automation complexity through integrated design.
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 solution prevents assembly inaccuracies, reduces labor time, and enhances productivity by enabling the production of high-performance micro fans with improved electrical performance through automated assembly.
Implementation Method 1
The stator module has a coreless coil and a lead frame
Implementation Method 2
the rotor further includes a magnet disposed related to the stator module
Data Source
AI summary
A brushless DC motor fan is provided. The brushless DC motor fan includes a rotor and a stator module. The rotor has a shaft disposed on an inner side of the stator module and rotating relative to the stator module. The stator module has a coreless coil and a lead frame, wherein the lead frame includes six pins electrically connected to the coreless coil.