Vertical Motor Bracket Holds Hall Sensor Circuit Board
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In rotating electric machines and starting generators, the accuracy of detecting the rotor magnet's position is compromised due to errors in sensor attachment and interference from magnetic noise from coils, leading to reduced detection accuracy.
Innovation Solution
A motor design featuring a shaft with a bearing mechanism, an armature, and a bracket that securely holds a circuit board with a Hall element, positioned to minimize attachment errors and electromagnetic noise interference, allowing for improved position detection of the rotor magnet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If magnetic sensors are disposed between teeth portions or overlapping generating coils, then the sensor structure can be simplified, but detection accuracy deteriorates due to magnetic noise from coils
Solution Approach 1:
The magnetic sensors are extracted from the noisy magnetic environment (between teeth portions or overlapping coils) and relocated to a position on the stator core that is spatially separated from the armature coils. This extraction removes the sensors from the harmful magnetic noise field while maintaining their detection function, thereby resolving the contradiction between structural simplicity and detection accuracy.
Solution Approach 2:
A dedicated sensor mounting structure (sensor holder or sensor case) is introduced as an intermediary component to position the magnetic sensors at an optimal location on the stator core. This intermediary structure enables precise positioning that avoids magnetic noise from coils while maintaining structural organization, thus resolving the contradiction between simplified sensor structure and accurate magnet position detection.
2Adaptability or versatility
If multiple attachment steps are used for sensors and circuit boards, then positioning flexibility increases, but cumulative attachment errors increase
Solution Approach 1:
The magnetic sensors and circuit board are merged into a single integrated assembly unit. The circuit board serves as both the mounting substrate for the sensors and the connection interface for electrical signals. This merging reduces the number of separate attachment steps from multiple (sensors to holder, holder to stator, circuit board to holder) to fewer steps, thereby reducing cumulative attachment errors while maintaining positioning flexibility through the integrated design.
Solution Approach 2:
The circuit board is given multiple functions: it serves as the electrical connection medium for the magnetic sensors, as the mounting structure for securing sensors to the stator core, and as the signal transmission interface to the control unit. This multi-functionality eliminates the need for separate sensor holders in some configurations, reducing attachment steps and cumulative errors while maintaining adaptability.
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 design enhances the accuracy of rotor magnet position detection by reducing attachment errors and electromagnetic interference, thereby improving the motor's operational precision.
Implementation Method 1
a circuit board on which a Hall element is mounted
Data Source
AI summary
A motor includes a shaft, a bearing, an armature disposed radially outward of the bearing, a bracket, a rotor, and a circuit board on which a Hall element is mounted. The rotor includes a rotor magnet radially opposed to the armature radially outward of the armature. The bracket includes a cylindrical portion including an outer peripheral surface to which the armature is fixed, a bracket bottom portion extending radially outward from a lower end portion of the cylindrical portion, a bracket side wall portion extending upward from an outer peripheral portion of the bracket bottom portion, and a board holding portion connected to the bracket side wall portion. The circuit board is held by the board holding portion. The Hall element is held by the bracket side wall portion.