Brushless Motor Direct Winding Connection Circuit
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Solution Overview
Problem
The existing brushless motor designs with intermediate terminals between power supply terminal elements and winding wires increase manufacturing costs, necessitating a cost-reduction approach.
Innovation Solution
An electric motor design that eliminates intermediate terminals by using an armature core with radially extending teeth, wire guides, and wire holding portions to directly connect winding terminal sections to power supply terminal elements, reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intermediate terminals are provided between power supply terminal elements and winding wires, then electrical connection is achieved, but manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates the intermediate terminals from the motor structure, achieving direct connection between power supply terminal elements and winding wires. This removal of unnecessary components reduces manufacturing costs while maintaining electrical connectivity through alternative means (direct wiring or integrated terminals formed as part of the stator structure).
Solution Approach 2:
The patent merges the function of intermediate terminals into the stator structure itself, where terminals are formed integrally with the stator core or housing. This consolidation eliminates separate intermediate terminal components and their associated assembly steps, reducing manufacturing complexity and cost while ensuring reliable electrical connection.
2Reliability
If intermediate terminals are used to connect power supply terminal elements and winding wires, then electrical connectivity is ensured, but device complexity increases
Solution Approach 1:
The patent removes intermediate terminals from the motor architecture, simplifying the overall structure. By eliminating these separate components, the patent reduces the number of parts that need to be manufactured, assembled, and maintained, thereby reducing device complexity while preserving electrical connectivity through direct connections.
Solution Approach 2:
The patent combines the terminal function directly into the stator structure, eliminating the need for separate intermediate terminal components. This integration reduces structural complexity by decreasing the number of discrete parts and simplifying the assembly process, while maintaining reliable electrical connection between power supply and winding wires.
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 allows for direct electrical connection of winding terminal sections to power supply terminal elements, eliminating the need for intermediate terminals and thereby reducing manufacturing costs while maintaining efficient electrical connectivity.
Implementation Method 1
Each of the wire guides is provided at a radial bottom portion of a corresponding one of the slots and guides the winding terminal section of a corresponding one of the winding wires toward the one axial side of the armature core. Each of the wire holding portions holds the winding terminal section of the corresponding one of the winding wires guided by the corresponding one of the wire guides.
Data Source
AI summary
Winding start sections and winding end sections of winding wires are pulled out from slots of an armature core and are guided by wire guides of an insulator. Thereafter, each corresponding one of the winding start sections and the winding end sections is guided by a corresponding winding holding portion and is directly connected to a corresponding one of power supply terminal elements of a circuit apparatus without using an intermediate terminal.