Motor Drive Device with Integrated Gearbox Control Module
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motor drive devices with built-in control modules are bulkier and more expensive due to the use of L-shaped PCBs and additional connectors, which increase size and cost.
Innovation Solution
A motor drive device design where the control module's PCB is accommodated within the gearbox housing, with solid contacts and Hall sensors for rotation detection, and a compact case that integrates with the gearbox and motor housing, using a press-fit mechanism and seal members for water resistance, reducing size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an L-shaped PCB and additional connector are used to accommodate the control module, then the control functionality is achieved, but the device size increases and manufacturing cost increases
Solution Approach 1:
The control module is merged with the gearbox housing by mounting the PCB directly onto the housing surface. The connector is integrated into the gearbox housing structure, eliminating the need for separate mounting brackets and reducing overall device volume while maintaining full control functionality.
Solution Approach 2:
The gearbox housing serves multiple functions: it encloses the gear mechanism, provides mounting surface for the control module, and integrates the connector structure. This multi-functionality reduces the need for additional components and minimizes device size.
2Reliability
If an L-shaped PCB and additional connector are used to accommodate the control module, then the control functionality is achieved, but the manufacturing cost increases
Solution Approach 1:
The control module components (PCB, connector, mounting structure) are merged into a single integrated assembly that mounts directly to the gearbox housing. This reduces the total part count, simplifies assembly operations, and lowers manufacturing costs while maintaining control functionality.
Solution Approach 2:
The complex L-shaped PCB structure and separate connector components are extracted from the design, replacing them with a simplified direct-mount PCB configuration that reduces manufacturing complexity and cost.
3Ease of operation
If the PCB is mounted outside the gearbox housing, then the control module is accessible, but the device becomes bulkier
Solution Approach 1:
The control module (PCB and connector) is nested within the gearbox housing boundaries, utilizing the existing housing space rather than adding external mounting structures. This maintains compact device volume while providing necessary control functionality.
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
The design results in a more compact and cost-effective motor drive device with improved water resistance and efficient electrical connections, suitable for applications like window lift mechanisms in vehicles.
Implementation Method 1
Hall sensors mounted to the PCB for detecting rotation of the shaft
Implementation Method 2
resilient motor terminals which grip the PCB
Implementation Method 3
a seal member is disposed in the interface between the gearbox housing and the case
Data Source
AI summary
A motor drive device comprises a motor, a gearbox mounted to the motor and a control module. The gearbox comprises a gearbox housing that has an opening facing the motor. The motor has a shaft that extends into the gearbox housing through the opening to drive a worm gear of the gearbox. The control module has a PCB mounted to the gearbox and most of the PCB is accommodated in the opening of the gearbox housing. The PCB extends in a plane substantially parallel to the shaft.