Integrated Motor Control Box and Rear Cover Design
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Solution Overview
Problem
Conventional brushless DC motors have a complex and costly structure due to an independent control box, leading to complicated electrical connections and a high failure rate from water ingress.
Innovation Solution
The control box is integrated as the rear end cover of the motor, with a fairlead connecting the motor casing cavity to the control box cavity, allowing for orderly wiring and water discharge, thereby protecting the control circuit board from water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control box is made as an independent aluminum casting piece mounted at the rear end cover, then the controller structure is complete, but the manufacturing cost increases and the structure becomes complicated
Solution Approach 1:
The control box is merged with the rear end cover to form an integrated structure. The rear end cover serves dual functions as both the structural cover and the control box housing, eliminating the need for a separate control box component. This integration reduces the total part count, simplifies manufacturing processes, and lowers production costs while maintaining the completeness and reliability of the controller structure.
2Ease of operation
If the main body and controller are respectively connected with lead wires, then the electrical connection is flexible, but the connection complexity increases and fault probability rises
Solution Approach 1:
The controller is integrated into the rear end cover structure, reducing the number of separate electrical connections needed. The control circuit board is mounted directly on the integrated control box, which is part of the motor housing, thereby reducing lead wire connections and associated complexity and potential failure points.
3Device complexity
If the control box has no water discharge capacity, then the structure is simple, but the control circuit board is easily soaked by water leading to high failure rate
Solution Approach 1:
The control box cavity is segmented from the motor housing cavity by a waterproof partition. This segmentation allows the control circuit board to be isolated in a protected compartment that is separated from water-prone areas, enabling water discharge functionality without requiring complete structural redesign. The partition creates distinct zones for electrical components and mechanical structures.
Solution Approach 2:
A waterproof partition acts as an intermediary barrier between the control circuit board and the motor housing cavity. This partition prevents water from reaching the control circuit board while still allowing the overall structure to maintain simplicity. The partition is a straightforward structural element that provides effective water protection without adding complex systems.
Data Source
AI summary
A combination of an outer motor and a control box therefor including an upper main body and a lower controller. The upper main body includes a casing, a front end cover, a rotor assembly, and a stator assembly. The controller includes a control box and a control circuit board, and the control box is sheathed in a tail end of the casing. A center of an upper bottom surface of the control box is arranged with a bearing chamber corresponding to that arranged at the front end cover. The control box forms a cavity downwards accommodating the control circuit board. A cover is mounted at the bottom of the control box. A fairlead arranged at an inner wall of the control box extends through the bottom of the motor casing to connect an empty cavity of the casing.