Vehicle Comfort Drive Motor PCB Connection for Winding Wire Ends
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Solution Overview
Problem
The existing electrically commutated electric motors face complexity and inefficiency in electrical contacting of winding wire ends with circuit carriers, requiring additional connecting elements that complicate the process and increase weight and installation space.
Innovation Solution
Direct electrical connection of winding wire ends to a circuit carrier with a recessed conductor track on the circuit board, eliminating the need for additional connecting elements, allowing for a compact and lightweight design with optional soldered or welded connections for enhanced security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional connecting elements (wire-hook-shaped stamped grid elements, hook-shaped elements, or clamping connections) are used to connect winding wire ends to the circuit carrier, then reliable electrical contact is achieved, but device complexity increases and installation space and weight are consumed
Solution Approach 1:
The patent merges the circuit carrier with the connecting element by integrating the electrical contact function directly into the circuit board structure. The contact pads and conductor tracks on the circuit carrier serve dual purposes: as structural support and as electrical connection elements, eliminating the need for separate wire hooks, stamped grid elements, or clamping connections.
Solution Approach 2:
The patent extracts the connecting element function from the traditional assembly and incorporates it directly into the circuit carrier. By designing the circuit board with integrated contact pads and conductor tracks that directly receive and electrically connect to the winding wire ends, the separate connecting elements are eliminated entirely.
2Reliability
If additional connecting elements are used to connect winding wire ends to the circuit carrier, then electrical contact is established, but weight and installation space increase
Solution Approach 1:
The circuit carrier is designed to combine structural support and electrical connection functions in a single integrated component. The contact pads and conductor tracks are built into the circuit board itself, merging what were previously separate elements (circuit carrier + connecting elements) into one unified structure, thereby reducing overall weight.
3Reliability
If additional connecting elements are used to connect winding wire ends to the circuit carrier, then electrical contact is established, but installation space increases
Solution Approach 1:
The integration of the circuit carrier with the electrical connection function eliminates the need for additional space-consuming connecting elements. The contact pads and conductor tracks are embedded within the circuit board structure, allowing for a more compact overall motor design with reduced installation space.
4Reliability
If a complex connection system with additional connecting elements is used, then reliable electrical contact is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the connection function from separate components and integrates it into the circuit carrier manufacturing process. The contact pads and conductor tracks are created during standard PCB fabrication, eliminating the need for separate manufacturing and assembly steps for connecting elements, thereby simplifying the overall manufacturing process.
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 solution simplifies and secures the electrical connection, reduces weight and installation space, and enables a compact, high-power-density motor design suitable for comfort drives in vehicles.
Implementation Method 1
the circuit carrier having a recess for passing through the winding wire end, the recess being designed as part of a clamping connection with a narrowed cutting area for the winding wire end
Implementation Method 2
the electrically conductive area being connected to the recess in the contact area of the winding wire end
Data Source
Figure 1~2
Figure 3
AI summary
An electrically commutated electric motor (10), which is suitable for a convenience drive of a vehicle, comprises a plurality of coil windings (23) which are arranged in a stationary manner. In this case, each coil winding (23) has at least one winding wire with a winding wire end (24, 25), and the winding wire end (24, 25) is electrically indirectly or directly connected to a circuit mount (28), for example a printed circuit board, for driving the coil windings (23). According to the invention, it is provided that the winding wire end (24, 25) is directly connected to an electrically conductive region, such as a conductor track of the circuit mount (28), and this connection is optionally situated on that side of the circuit mount (28) which is averted from the coil winding.