Brushless Motor End Shield with Integrated Sensor Receptacle
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The precise positioning and alignment of non-output-side end shields, rotor shafts, sensor circuit boards, and sensor magnetic rings in brushless electric motors are challenging due to tight tolerances, often leading to errors and suboptimal commutation in conventional designs.
Innovation Solution
A non-output-side end shield with integrated slide-in elements and a sensor receptacle, formed as a one-part component, which includes radially, tangentially, and axially oriented centering surfaces for precise alignment with the stator laminated core, along with holding elements for secure attachment, facilitating easier assembly and improved commutation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional non-output-side end shields with separate components are used, then assembly flexibility is maintained, but positioning precision and alignment accuracy deteriorate due to cumulative errors in sequential assembly
Solution Approach 1:
The sensor receptacle is integrated directly into the non-output-side end shield as a one-piece component, eliminating separate mounting operations and cumulative positioning errors. This merging of components ensures precise alignment between the sensor circuit board and rotor shaft while reducing assembly complexity through fewer parts.
2Reliability
If tight tolerances are enforced for precise alignment, then commutation quality improves, but manufacturing time and costs increase significantly
Solution Approach 1:
The sensor receptacle is pre-positioned and precisely aligned during the manufacturing of the non-output-side end shield itself, rather than requiring post-assembly adjustments. This preliminary action ensures accurate alignment is built-in from the start, eliminating time-consuming manual positioning and measurement operations during final assembly.
3Ease of manufacture
If sequential assembly of individual components is used, then ease of manufacture is maintained, but cumulative errors exceed required tolerances
Solution Approach 1:
By integrating the sensor receptacle into the end shield as a single component, the invention reduces the number of sequential assembly steps while ensuring precise alignment is inherent to the design. This eliminates cumulative errors that would otherwise accumulate across multiple separate component interfaces.
Data Source
AI summary
A non-output-side end shield (100) for a brushless electric motor (500) is provided, including a centrally arranged bearing seat (110) for accommodating a non-output-side rotor bearing (510) for a rotor shaft (560) of the brushless electric motor (500), the non-output-side end shield (100) including a sensor receptacle (150), which is used as a carrier for a sensor circuit board (550) for detecting the rotational position of the rotor shaft (560), the non-output-side end shield (100) and the sensor receptacle (150) being formed together as a one-part component.