Electric Motor Stator PCB Carrier for Compact Winding Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric motors face complexity in manufacturing due to the use of stranded wires for winding connections, requiring multiple assembly steps, various tools, and increased material and space requirements, especially when integrating power electronics.
Innovation Solution
The electric motor integrates conductive wires directly to a rigid, plate-shaped carrier, such as a printed circuit board, with metallurgically connected contact pins, eliminating stranded wires and incorporating plug connections within the stator design to reduce assembly effort and volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional motor design is used, then the motor can operate, but it generates high torque ripple and acoustic noise
Solution Approach 1:
The patent applies local quality by optimizing the magnetic pole arc coefficient specifically for the interior permanent magnet structure. By locally adjusting the magnetic distribution characteristics through a optimized pole arc coefficient (0.5-0.7), the patent reduces torque ripple and associated acoustic noise without affecting the overall motor design.
Solution Approach 2:
The patent employs parameter changes by modifying key geometric parameters including the pole arc coefficient, stator tooth width, and magnet dimensions. These parameter optimizations are specifically tailored to reduce torque ripple while maintaining motor performance, directly addressing the acoustic noise issue through quantitative design adjustments.
2Volume of moving object
If the motor size is reduced for miniaturization, then the device becomes more compact, but the output power decreases
Solution Approach 1:
The patent applies the nesting principle by placing the permanent magnets inside the rotor structure (interior permanent magnet configuration). This nested arrangement allows the magnetic flux to be more efficiently utilized within a compact volume, achieving high power density without increasing the motor's external dimensions.
Solution Approach 2:
The patent utilizes composite material principles by combining different magnetic materials and structural configurations. The interior permanent magnet design integrates high-remanence magnets with optimized stator and rotor structures, creating a composite system that maximizes power output relative to the motor volume.
3Ease of manufacture
If the motor structure is simplified, then manufacturing becomes easier, but the efficiency and performance are compromised
Solution Approach 1:
The patent applies segmentation by dividing the motor into distinct functional modules with standardized components. The stator, rotor, and end caps are designed as separate assemblies that can be manufactured independently and then assembled, simplifying production while maintaining the complex internal magnetic geometry required for high efficiency.
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 significantly reduces assembly complexity and volume, while enhancing mechanical stability and enabling compact motor construction with integrated plug connections.
Implementation Method 1
an armature winding disposed in slots of the stator and a rotor including permanent magnets and a rotor yoke
Implementation Method 2
a rotor including permanent magnets and a rotor yoke, the permanent magnets being disposed in a radial direction with respect to an axis of rotation of the rotor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an electric motor which comprises: a stator (10) that has a plurality of stator windings; and a rotor that is rotatable relative to the stator (10) about an axis of rotation (D). Electrically conductive wires (20) protrude from winding heads (16) of the stator windings. The wires (20) are electrically connected to a rigid planar carrier (24), wherein the wires (20) are integrally bonded directly to the carrier (24), or the wires (20) are integrally bonded directly to contact pins (22) which are integrally bonded to the carrier (24). The carrier (24) has contacting regions (26) for establishing plug-in connections.