Brushless Motor Bracket Cutout for Easier PCB Terminal Soldering
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Solution Overview
Problem
The manufacturing process of brushless motors is complicated due to the interference between soldering tools and the peripheral walls of the intermediate bracket and end cover, making it difficult to solder terminals to the circuit board without damaging the motor components.
Innovation Solution
A motor design featuring a bracket with a board support portion and a wall portion that includes a cutout portion, allowing the soldering iron to easily access the terminal connection area without interfering with the motor's structural components, and a bus bar assembly with phase and signal bus bars embedded in the bracket for improved connectivity and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the circuit board is disposed inside the peripheral wall of the intermediate bracket, then the structural integrity is improved, but the soldering process becomes complicated due to interference between soldering tools and the peripheral wall
Solution Approach 1:
The intermediate bracket is segmented by providing an opening in its peripheral wall, dividing the enclosed space into accessible regions. This segmentation allows soldering tools to access the circuit board through the opening while maintaining the overall structural integrity of the bracket.
Solution Approach 2:
The opening in the intermediate bracket acts as an intermediary passage, enabling the soldering tool to reach the circuit board without direct contact with the peripheral wall. This mediator structure resolves the interference problem while preserving the protective enclosure.
2Object-affected harmful factors
If the peripheral wall completely surrounds the circuit board, then protection is improved, but accessibility for soldering tools deteriorates
Solution Approach 1:
The peripheral wall is segmented by introducing an opening, creating a balance between protection and accessibility. The opening allows soldering tools to access the circuit board while the remaining enclosed structure continues to provide protection.
Solution Approach 2:
The peripheral wall has different properties in different locations: it is enclosed in most areas for protection, but has an opening in the axial direction to allow tool access. This local differentiation resolves the contradiction between protection and accessibility.
3Strength
If the wall portion completely surrounds the circuit board, then structural support is improved, but manufacturing complexity increases due to limited tool access
Solution Approach 1:
The wall portion is segmented by providing a cutout, simplifying the manufacturing process. The cutout allows soldering tools to access terminal connection portions without requiring complex disassembly or positioning procedures, reducing manufacturing complexity while maintaining structural support.
Solution Approach 2:
The cutout portion is extracted from the wall portion, creating an opening that facilitates tool access. This extraction simplifies the manufacturing process by eliminating the need for complex tool navigation around complete enclosures.
Data Source
AI summary
A motor includes a rotor configured to rotate about a central axis extending in an up-down direction, a stator located radially outside the rotor, a bracket located above the stator, a circuit board held by the bracket and disposed along a plane perpendicular to an axial direction, and a bus bar held by the bracket and connected to the circuit board at a terminal connection portion. The bracket includes a board support portion supporting the circuit board from below, and a wall portion protruding upward to be higher than the board support portion and surrounding the circuit board. The wall portion has a cutout portion extending downward from an upper end of the wall portion.