Externally Excited Machine PCB Layout for Uneven Contact Heights
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Solution Overview
Problem
Externally excited electric machines face challenges in integrating exciter and stator control circuits onto a common circuit board due to differing height levels and dimensions of electrical contacts, necessitating separate circuit boards and increased material and manufacturing costs.
Innovation Solution
The exciter and stator control circuits are mounted on a common circuit board with connectors, such as bonding wire and/or bonding bands, that can bridge the height difference between electrical contacts, allowing for flexible geometric adaptation to connect sites with varying distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate circuit boards are used for exciter control circuit and stator control circuit, then electrical connections can be established, but material costs and manufacturing complexity increase
Solution Approach 1:
The patent combines the exciter control circuit and stator control circuit onto a single circuit board, eliminating the need for separate circuit boards. This merging reduces material costs, simplifies manufacturing, and decreases overall device complexity while maintaining reliable electrical connections through the common board structure.
Solution Approach 2:
The common circuit board serves multiple functions by accommodating both the exciter control circuit and stator control circuit on the same substrate. This multi-functional approach allows a single component to perform what previously required separate dedicated circuit boards, reducing overall system complexity.
2Device complexity
If connectors are adapted to bridge height differences, then a common circuit board can be used, but connector geometrical complexity increases
Solution Approach 1:
The connectors are designed with geometrical adaptations that allow them to accommodate height differences between electrical contacts. This dynamic geometric design enables the connectors to bridge varying distances and align properly with contacts at different levels, facilitating the use of a common circuit board despite manufacturing tolerances and contact height variations.
Solution Approach 2:
The connector geometry is specifically adapted to change parameters such as length, angle, or positioning to bridge the height difference between electrical contacts. By modifying the connector's physical parameters, the design enables reliable electrical connection between components mounted at different heights on the common circuit board.
3Ease of manufacture
If electrical contacts are at different heights, then power module connections are simplified, but common circuit board integration becomes difficult
Solution Approach 1:
The adapted connectors serve as intermediary elements between the electrical contacts at different heights and the common circuit board. These connectors mediate the connection by accommodating height variations through their geometrical design, allowing power modules with contacts at different levels to be integrated onto a single circuit board without requiring precise height matching.
Data Source
AI summary
An externally excited electric machine includes an exciter power circuit connected to a rotor winding, a stator power circuit connected to a stator winding, an exciter control circuit connected by at least a first connector to the exciter power circuit, and a stator control circuit connected by at least a second connector to the stator power circuit. The exciter control circuit and the stator control circuit are mounted on a common circuit board. The first connector is connected to a first electrical contact of the exciter power circuit, and the second connector is connected to a second electrical contact of the stator power circuit. The first electrical contact and the second electrical contact are at different heights in relation to the circuit board. The first or the second connector has a geometrical form that bridges over a height difference between the first electrical contact and the second electrical contact.