Modular Hall Sensor Assembly for Brushless DC Motor Repair
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Solution Overview
Problem
Existing brushless DC motors with Hall effect sensors are not easily replaceable if a sensor fails, leading to the entire motor being scrapped, which is costly and time-consuming due to the need for recalibration and replacement.
Innovation Solution
A modular Hall effect sensor array is designed for easy replacement within the brushless DC motor, where the Hall effect sensor assembly is removably coupled to a carrier plate, allowing for individual module replacement without recalibration, using a fastening mechanism and overmolding to maintain alignment and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Hall effect sensors are permanently potted or overmolded to the motor assembly, then mechanical shock, vibration, and contamination resistance is improved, but replaceability of individual sensors deteriorates
Solution Approach 1:
The sensor assembly is segmented into modular components: individual Hall effect sensors are mounted on a circuit board that is separately replaceable from the motor assembly. The circuit board is secured to the motor housing with screws rather than permanent bonding, allowing the board to be removed and replaced without replacing the entire motor.
2Measurement precision
If Hall effect sensors are adjusted angularly during motor assembly, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The angular positioning of the Hall effect sensors is predetermined during circuit board manufacturing. The sensors are mounted at precise angles on the circuit board in a factory setting, eliminating the need for complex angular adjustment procedures during motor assembly. This preliminary positioning action transfers the precision requirement to the manufacturing stage rather than the assembly stage.
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
Enables fast and cost-effective replacement of failed Hall effect sensors, extending the motor's lifespan and reducing waste by allowing individual module replacement without recalibration, thus maintaining motor performance and reliability.
Implementation Method 1
A brushless DC motor is provided. The brushless DC motor comprises a motor housing around an axis, a stator assembly inside the motor housing, a carrier plate fixed relative to the stator assembly, and a Hall effect sensor assembly removably coupled to the carrier plate.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A brushless DC motor (100) is provided. The brushless DC motor (100) comprises a motor housing (102) around an axis (101), a stator assembly (104) inside the motor housing (102), a carrier plate (120) fixed relative to the stator assembly (104), and a Hall effect sensor assembly (130) removably coupled to the carrier plate (120). A method of making a brushless DC motor (100) is also provided comprising fixing a carrier plate (120) relative to a stator assembly (104) of a brushless DC motor assembly, and fixing a first Hall effect sensor array (130) to the carrier plate (120).