Hall Effect Sensor Mounting Bracket for Motor
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Solution Overview
Problem
The existing installation methods for Hall effect sensors in motors are unreliable, making it difficult to position the control circuit board and prone to detachment, and the sensors are susceptible to high voltage breakdown.
Innovation Solution
A structure comprising a mounting bracket, supporting columns, and a mounting plate that securely embeds the Hall effect sensor within a cavity, allowing for easy and firm installation, increased creepage distance from coil windings, and enhanced protection against high voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the Hall effect sensor is installed on the control circuit board mounted on the end insulator or rear end cover, then the installation is simple, but the installation is unreliable and the sensor tends to detach
Solution Approach 1:
A mounting bracket is introduced as an intermediary component between the control circuit board and the end insulator. The bracket includes a mounting plate that contacts the end insulator and a mounting bracket that secures the Hall effect sensor, providing a more reliable attachment mechanism while maintaining installation simplicity
Solution Approach 2:
The mounting structure is divided into separate components: a mounting plate for attachment to the end insulator, a mounting bracket for securing the sensor, and supporting columns for structural support. This segmentation allows each component to perform its specific function optimally, improving overall reliability
2Ease of operation
If the control circuit board is mounted on the end insulator, then the Hall effect sensor can be installed, but the control circuit board is difficult to position accurately
Solution Approach 1:
The mounting plate is pre-formed with specific geometric features including a circular yoke, teeth, and winding slots that provide predetermined positioning locations. This preliminary preparation of the mounting structure enables accurate positioning of the control circuit board and Hall effect sensor during assembly
3Volume of moving object
If the Hall effect sensor is installed close to the coil windings, then the structure is compact, but the creepage distance is insufficient and the sensor is susceptible to high voltage breakdown
Solution Approach 1:
The mounting structure utilizes the radial dimension of the end insulator by extending supporting columns and mounting plates outward from the center. This dimensional arrangement increases the creepage distance between the Hall effect sensor and coil windings in the radial direction while maintaining overall structural compactness
4Device complexity
If a simple mounting structure is used, then the device complexity is low, but the installation is unreliable and the sensor is prone to detachment
Solution Approach 1:
The mounting plate, mounting bracket, and supporting columns are combined into an integrated mounting structure that functions as a unified assembly. This merging provides multiple attachment points and structural support simultaneously, improving reliability without significantly increasing device complexity
Data Source
AI summary
A structure for mounting a Hall effect sensor, the structure including: a mounting bracket, a mounting plate, a left supporting column, a right supporting column, and a first supporting column. The left supporting column and the right supporting column are protruded upwards from top surfaces of two adjacent teeth at the inner side of a certain winding slot, respectively. The first supporting column is protruded upwards from the top surface of the circular yoke at the outer side of the winding slot. The mounting plate is disposed on top surfaces of the first supporting column, the left supporting column, and the right supporting column. The mounting bracket is installed at the bottom of the mounting plate. The Hall effect sensor is installed in the mounting bracket.