DC Motor Plug Connection Stability for Liquid Pumps
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Solution Overview
Problem
Existing electrically commutated DC motors for liquid pumps are prone to damage and failure under extreme loads due to unstable connections and direct contact with circuit boards, leading to reduced reliability and lifespan.
Innovation Solution
The DC motor design includes a disk-shaped pump rotor with a permanent magnet, axially aligned stator poles, and a partition separating pump and dry spaces, featuring insulation elements, mechanically fastened stator windings, and separate circuit boards with conductor tracks and a contact support to secure plug connections, preventing mechanical and electronic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If connections are held only in a plug cover without special securing measures and in direct contact with a circuit board, then the structure is simple, but the reliability deteriorates under extreme loads and after longer running time
Solution Approach 1:
The connection structure is segmented into multiple functional components: a contact support element separate from the circuit board, insulation elements distinct from the housing, and a dedicated plug cover. This segmentation allows each component to perform its specific function optimally while reducing stress concentration points that would compromise reliability under extreme loads.
Solution Approach 2:
The contact support element acts as an intermediary between the plug cover and the circuit board, providing mechanical support and electrical connection while isolating the circuit board from direct mechanical stress. The insulation elements serve as intermediaries between the stator poles and the contact support, preventing electrical discharge and mechanical stress transmission to sensitive components.
2Device complexity
If the circuit board is directly connected to winding connections without insulation elements, then the device complexity is reduced, but harmful factors increase due to potential electrical discharge and mechanical stress
Solution Approach 1:
Insulation elements are positioned as intermediaries between the stator poles and the contact support element, providing electrical isolation to prevent discharge and mechanical isolation to reduce stress transmission. These elements create protective zones around critical electrical components without significantly increasing overall device complexity.
Solution Approach 2:
The insulation elements function as thin film barriers that provide effective electrical and mechanical protection. These film-like structures conform to the geometry of the stator poles and contact support, creating flexible protective layers that accommodate thermal expansion and vibration while maintaining isolation properties.
3Ease of manufacture
If multiple components are assembled without a dedicated contact support, then the assembly process is simpler, but the reliability of plug connections deteriorates
Solution Approach 1:
The contact support element performs multiple functions simultaneously: it provides mechanical support for the plug cover, creates electrical connections to the circuit board, establishes precise positioning for the insulation elements, and distributes mechanical loads. This multi-functionality consolidates several assembly steps into a single integrated component, improving reliability without significantly complicating manufacturing.
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 configuration enhances the motor's reliability and longevity by isolating sensitive components and securing connections, ensuring stable assembly and effective diversion of mechanical loads.
Implementation Method 1
an essentially disk-shaped pump rotor (6) mounted to a motor shaft (41) to rotate in the pump housing (3), consisting of an impeller (7) with several pump vanes and a permanent magnet (8)
Implementation Method 2
a plurality of axially aligned wound stator poles (14) with a plurality of stator windings (16) each having first and second winding ends
Data Source
AI summary
An electrically commutated DC motor (1) for a liquid pump (2) with a pump housing (3) with a suction connector (4) and a pressure connector (5) for connection to a hydraulic circuit, an essentially disk-like pump rotor (6) mounted to rotate in the pump housing, consisting of an impeller (7) with several pump vanes and a permanent magnet (8), a partition (11) separating a pump space (9) from a dry space (10), in which the partition is arranged in an axial gap (12) between the pump rotor (6) and several axially aligned wound stator poles (14) of the DC motor. The present invention configures a DC motor, so that it can be installed simply and reliably, is designed particularly robust and therefore has a very long operating lifetime.