Motor Interface Board for Reliable Brushless DC Motor Connections
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Solution Overview
Problem
Existing ultracompact, high-performance motor controllers face challenges with unreliable mechanical and electrical connections to brushless DC motors, requiring manual soldering that can lead to cold solder joints and complex replacement processes, especially when positioned within larger assemblies.
Innovation Solution
A motor interface board (MIB) provides reliable mechanical and electrical connections between the motor controller and the motor, allowing for quick and easy swapping of the controller without the need for changes to the controller component, using a combination of printed circuit boards, connectors, and mounting mechanisms to ensure robust and stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering is used to connect motor controller to motor, then electrical connections can be made, but cold solder joints occur and quality control becomes inconsistent
Solution Approach 1:
The patent introduces a motor interface board as an intermediary component between the motor controller and the motor. This board provides standardized connection interfaces that eliminate the need for manual soldering of the motor controller to the motor, thereby improving connection reliability while simplifying the manufacturing process. The interface board acts as a mediator that handles the electrical connections through standardized connectors.
2Volume of moving object
If motor controller is integrated directly to motor body, then compact design is achieved, but replacement becomes difficult and time-consuming
Solution Approach 1:
The patent segments the motor system into distinct modular components: the motor body, the motor interface board, and the motor controller. This segmentation allows the controller to be easily separated and replaced by simply disconnecting it from the interface board, while still maintaining a compact integrated design when assembled. The modular architecture enables quick replacement without affecting the overall compactness of the motor assembly.
3Measurement precision
If rigid mechanical connection is used for rotor-position sensing, then sensing accuracy is maintained, but mechanical stress on connectors increases
Solution Approach 1:
The motor interface board serves as a mediator that provides a stable mounting surface for the motor controller while maintaining precise alignment for rotor-position sensing. The board's rigid structure ensures accurate positioning of the controller's sensors relative to the motor's rotor position targets, while the board itself absorbs mechanical stresses rather than transmitting them directly to the connector interfaces.
Data Source
AI summary
Apparatus for connecting a motor controller to an electrical motor, said apparatus comprising:a motor interface board;a mounting mechanism for mechanically connecting said motor interface board to the electrical motor;at least one input lead for electrically connecting said motor interface board to at least one of an electrical power source and an electrical signal source;at least one output lead for electrically connecting said motor interface board to the electrical motor; andat least one connector for mechanically and electrically connecting said motor interface board to the motor controller.