Motor Module PCB Integration for Miniaturization
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Solution Overview
Problem
Current miniature motor modules face challenges in miniaturization due to complex motor systems, poor rotation efficiency, and increased thickness, making them difficult to assemble and integrate with circuit boards effectively.
Innovation Solution
A motor module design featuring a bearing housing with a loading base and protruding portion, an electric unit with a printed circuit board (PCB) and sensing elements, and a magnetic rotor unit stacked on the bearing, utilizing semiconductor wiring to form signal circuits and motor windings, allowing for compact integration and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional motor systems with mechanical automation are used, then motor function is achieved, but volume cannot be miniaturized due to complex structure
Solution Approach 1:
The patent merges the circuit board with the motor system by directly forming signal circuits and motor windings on the same PCB. This integration eliminates the need for separate wiring harnesses and reduces the number of components, thereby miniaturizing the overall motor module volume while simplifying the structure.
Solution Approach 2:
The PCB serves multiple functions simultaneously: it acts as the circuit board for signal processing, the stator core for motor operation, and the mounting base for the magnetic rotor unit. This multi-functionality reduces the number of separate components needed, achieving both volume reduction and structural simplification.
2Power
If high slot occupation rate by motor windings is used, then motor function is improved, but thickness of motor system increases
Solution Approach 1:
The patent transitions from traditional three-dimensional motor winding arrangements to a planar two-dimensional winding layout on the PCB. This dimensional change allows for high slot occupation rates and improved motor power while maintaining a thin profile, as the windings are distributed across the surface area rather than stacked in thickness.
3Ease of manufacture
If separate assembly of motor system and circuit board is used, then manufacturing flexibility is maintained, but assembly difficulty increases and automation is hard to apply
Solution Approach 1:
By integrating the circuit board and motor system into a single PCB structure, the patent eliminates the need for separate assembly operations. The motor windings and signal circuits are formed in the same manufacturing process, making the entire motor module suitable for automated manufacturing while significantly easing the assembly process.
4Volume of moving object
If conventional wiring methods are used, then electrical connections are established, but space size increases and miniaturization is hindered
Solution Approach 1:
The patent extracts the wiring function from traditional separate cables and connectors and integrates it directly into the PCB structure. The motor windings and signal circuits are formed as traces on the same board, eliminating external wiring harnesses and reducing the overall space required for electrical connections.
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 simplifies and miniaturizes the motor module structure, improves yield rates, and facilitates easier assembly by integrating signal circuits and motor windings on the PCB, while reducing motor volume and enhancing assembly efficiency.
Implementation Method 1
when electric current passes the motor windings, the motor windings and the magnetic rotor unit generate a flux linkage induction, so as to drive the magnetic rotor unit to rotate relative to the PCB
Data Source
AI summary
A motor module includes a bearing housing having a loading base, an electric unit, a bearing, and a magnetic rotor unit disposed on the bearing. In addition, a protruding portion is extending from the loading base, and the electric unit includes a printed circuit board (PCB) and sensing elements, wherein the PCB is utilized for disposing the loading base thereon. Moreover, signal circuits and motor windings are formed on the PCB around the loading base, the sensing elements are disposed around the motor windings, and the bearing is disposed at the protruding portion. Besides, the magnetic rotor unit is disposed on the motor windings, keeping a gap with the PCB; therefore, when electric current passes the motor windings, the magnetic rotor unit and the motor windings generate a flux linkage induction, so as to drive the magnetic rotor unit to rotate relative to the PCB.