Brushless Motor Phase Wire Adapter for Single-Plane PCB Assembly
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Solution Overview
Problem
Existing drive apparatuses for motor vehicles, particularly window lifting mechanisms, face challenges in automating the precise bundling and fixing of phase connections for brushless electric motors, requiring multiple axes for assembly and exposing components to moisture and temperature fluctuations.
Innovation Solution
A drive apparatus with a brushless electric motor featuring a connection adapter that orients phase connection wires radially, allowing for automated insertion of a printed circuit board in a single plane, using a connection adapter with wire openings and joining elements for precise alignment and fixation, reducing complexity and enhancing robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If phase connection wires are manually bundled and fixed with auxiliary means, then positioning accuracy is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The connection adapter is pre-configured with wire openings at specific positions and orientations before assembly. This preliminary preparation enables automated positioning of phase connection wires without requiring manual bundling or additional fixing means during assembly, thus achieving positioning accuracy while reducing manufacturing complexity
Solution Approach 2:
The connection adapter serves as an intermediary component between the stator winding and the printed circuit board. It provides a structured interface with wire openings that guide and position the phase connection wires, eliminating the need for manual auxiliary means while ensuring accurate alignment during automated assembly
2Manufacturing precision
If printed circuit board is inserted with phase connection wires requiring two movement axes, then precise alignment is achieved, but assembly complexity and time increase
Solution Approach 1:
The connection adapter is pre-configured with wire openings that are precisely positioned and oriented to match the printed circuit board connection locations. This preliminary preparation enables the printed circuit board to be inserted in a single linear motion without requiring complex multi-axis movement, thus reducing assembly time while maintaining alignment precision
Solution Approach 2:
The wire openings in the connection adapter are arranged in a pattern that transforms the alignment requirement from a multi-dimensional problem requiring two movement axes into a single-dimensional problem solvable by linear insertion. The spatial arrangement of wire openings provides the necessary alignment constraints in a simplified manner
3Ease of manufacture
If phase connection wires are exposed during transport and assembly, then assembly simplicity is maintained, but reliability decreases due to moisture and temperature exposure
Solution Approach 1:
The connection adapter provides a nested protective structure where wire openings are formed within the adapter body. Phase connection wires pass through these openings while being enclosed and protected by the adapter housing, shielding them from moisture and temperature fluctuations during transport and assembly while maintaining assembly simplicity
Solution Approach 2:
The connection adapter acts as a protective shell that encloses and protects the phase connection wires. The adapter's structure provides a barrier against environmental factors such as moisture and temperature while allowing the wires to pass through designated openings, thus improving reliability without complicating the assembly process
Data Source
AI summary
A drive device contains a brushless electric motor having a rotor with a rotor shaft coupled to the rotor, and a stator which has a stator support and a rotating field winding or stator winding with a number of phase connection wires. A gear mechanism housing is provided and has an electronics compartment with a printed circuit board which is accommodated in the compartment and has connection points for the phase connection wires. A housing shaft is provided which is coaxial with respect to the axis of rotation of the rotor shaft and in which the stator is accommodated together with the stator support and the rotor is accommodated together with the rotor shaft. A connection adapter is provided in which the phase connection wires are oriented radially and are accommodated in a connection grid which is adapted to the connection points of the printed circuit board.