Synchronous Motor Coil Connection Layout Without Bulky PCB Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting coils in electric motors, such as those used in tubular actuators, face challenges with size constraints and increased complexity and cost due to bulky plastic components and the need for printed circuits, which are unnecessary in sensorless motors.
Innovation Solution
A synchronous electric motor design featuring a dedicated support part with a rigid substrate between the stator's support part and flange, allowing coil connections without direct attachment to the stator or printed circuits, facilitating simpler manufacturing and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire ends are directly connected to a printed circuit board mounted on the stator, then electrical connection is achieved, but manufacturing complexity and cost increase due to additional soldering steps
Solution Approach 1:
The patent introduces an intermediate connection element (metal lug or bridge) that mediates between the wire end and the printed circuit board. This intermediary component simplifies the connection process by providing a pre-formed connection point that requires minimal additional manufacturing steps, thereby reducing overall manufacturing complexity while achieving reliable electrical connection.
Solution Approach 2:
The connection system is segmented into distinct functional components: the wire end, the intermediate connection element (metal lug/bridge), and the printed circuit board. This segmentation allows each component to be optimized independently and assembled through simpler processes, reducing the complexity of the overall manufacturing process compared to direct wire-to-PCB soldering.
2Ease of operation
If a printed circuit board is used for coil connections, then electrical connection is achieved, but device size increases due to the necessary space for the PCB
Solution Approach 1:
The patent implements nesting by placing the printed circuit board within the hollow interior space of the stator body. The PCB is positioned in the available void space, allowing it to be nested within the motor structure rather than adding external volume. This nesting approach enables electrical connections to be made without increasing the overall motor dimensions.
Solution Approach 2:
The connection system utilizes the internal three-dimensional space of the stator by positioning the PCB in the hollow interior. This dimensional approach allows the PCB to be accommodated within the existing motor volume by utilizing the internal cavity, rather than requiring additional external space, thus maintaining compact motor dimensions while enabling sophisticated electrical connections.
3Ease of operation
If a printed circuit board is used for coil connections, then electrical connection is achieved, but device cost increases due to unnecessary PCB components
Solution Approach 1:
The patent extracts and removes unnecessary components from the system by implementing a simplified PCB design that contains only the essential connection traces and mounting points required for wire connections. By taking out unnecessary electronic components and circuitry, the design reduces overall device complexity and cost while maintaining the essential electrical connection function.
Solution Approach 2:
The patent applies partial action by implementing a PCB with minimal functionality - only the specific traces and connection points necessary for coil connections are included. This partial implementation approach avoids the cost and complexity of a full-featured PCB while still achieving the required electrical connection function, thereby reducing device complexity and cost.
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 simplifies the coil connection process, reduces material volume, and eliminates unnecessary components, making it suitable for compact motor applications while maintaining efficient operation.
Implementation Method 1
A synchronous electric motor (1) comprises a stator (2), a rotor (3), a support piece (23) attached to the stator on the side of its first flange (22), and a printed circuit board (25) with a rigid substrate sandwiched between the support piece and the flange
Implementation Method 2
The stator is formed by a stator core containing pole pieces that support windings or coils. These pole pieces are distributed along a peripheral wall of the stator, specifically on an internal wall of the stator body. The coils are designed to receive a selective electrical current from an external source, generating a magnetic induction that drives the rotor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
This synchronous electric motor comprises a tubular stator (2) and a rotor rotating inside the stator (2) about an axis of rotation (X) coaxial with the stator, the stator including coils each formed by winding an electrically conductive wire. The stator (2) comprises: - a flange (22) securely mounted on the end of the stator; - an electrically insulating support part (23), secured to the flange and provided with electrical connectors (233), each including a power supply terminal (2331) and two curved blades (2332, 2333) electrically connected with the corresponding power supply terminal, the curved blades of each connection element each being electrically connected to an end portion of wire from a coil, each connector forming a common connection point between two coils associated with different electrical power phases of the motor.