Brushless Motor Phase Connection Assembly With PCB Socket Alignment
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Solution Overview
Problem
Existing drive devices, such as electromotive adjustment drives for motor vehicles, face challenges in efficiently and reliably connecting phase connections of brushless electric motors to printed circuit boards, often requiring time-consuming manual soldering or complex plug-in connections, which are demanding in terms of components and space.
Innovation Solution
A drive device design featuring a brushless electric motor with a stator and rotor housed in a common body, where phase connections are bent and guided into radially-oriented joining positions, using a sleeve-form guide element with reception grooves and capping bars, allowing for automatic and precise alignment with connection sockets on the printed circuit board, enabling fail-safe and positionally accurate soldering or plug-in connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering or complex plug-in connections are used for phase connections, then electrical connection reliability is improved, but assembly time and device complexity increase
Solution Approach 1:
The phase connections are pre-bent into the radial joining position during stator manufacturing, and the guide element with reception grooves is pre-configured to guide these connections. This preliminary preparation eliminates the need for time-consuming manual alignment and soldering during final assembly, while maintaining reliable electrical connections through the pre-established geometric precision.
Solution Approach 2:
The guide element acts as an intermediary component between the phase connections and the printed circuit board. It provides the reception grooves that automatically align and position the phase connections, facilitating accurate connection without requiring complex manual intervention or additional alignment mechanisms.
2Reliability
If manual soldering or complex plug-in connections are used for phase connections, then electrical connection reliability is improved, but device complexity increases
Solution Approach 1:
The guide element integrates multiple functions into a single component: it provides structural support for the phase connections, guides their positioning through reception grooves, and facilitates alignment with the printed circuit board. This merging of functions reduces the number of separate components needed and simplifies the overall connection system while maintaining reliability.
Solution Approach 2:
The guide element with its reception grooves enables the phase connections to self-align and self-position during assembly. The geometric design of the grooves automatically guides the bent phase connections into the correct radial joining position, eliminating the need for complex external alignment mechanisms or manual adjustment procedures.
3Extent of automation
If phase connections are bent into radial joining position, then automated assembly is enabled, but manufacturing precision requirements increase
Solution Approach 1:
The phase connections are bent into a specific radial joining position with defined geometric parameters during stator manufacturing. This parameter change from random wire arrangement to precise radial orientation enables automated assembly processes while the precision is maintained through controlled bending operations and standardized geometric specifications.
Solution Approach 2:
The guide element provides localized precision features in the form of reception grooves at specific positions. These grooves concentrate the precision requirements to specific locations where they are most needed (at the connection points), rather than requiring high precision throughout the entire assembly process. This localized approach to precision makes automated assembly feasible.
Data Source
AI summary
A drive device, having a drive housing with a brushless electric motor which can be installed therein and has a stator winding and a rotor and motor electronics with a printed circuit board, the electric motor being insertable into the drive housing via a housing opening. A main stator body has a number of stator teeth which are arranged in a star shape and around which the stator winding is wound, a number of phase connections of the stator winding being guided into an in particular radially oriented joining position. The printed circuit board has a number of connection sockets corresponding to the number of phase connections, said connection sockets receiving the phase connections as the electric motor is inserted into the drive housing.