Motor Circuit Substrate Layout for Axial Miniaturization
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Solution Overview
Problem
Existing dynamo-electric machines face challenges in miniaturization in the axial direction while incorporating a circuit substrate for control operations.
Innovation Solution
The dynamo-electric machine design includes a tubular stator, rotor, and a bottomed tubular case with a circuit substrate disposed between the stator and an end cover, utilizing insulation sheets with high LOI values and a resin to integrate and insulate components, allowing for compact axial dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the circuit substrate is disposed inside the case in conventional structures, then the motor can be controlled, but the axial length increases and miniaturization is difficult
Solution Approach 1:
The circuit substrate is merged with the end cover by disposing it on the outer peripheral side of the stator core, allowing the circuit substrate and end cover to form an integrated structure. This combining approach eliminates the need for separate accommodation spaces, thereby reducing the axial length while maintaining control functionality.
Solution Approach 2:
Instead of disposing the circuit substrate axially inside the case, the invention repositions it to the outer peripheral side of the stator core, utilizing the radial dimension. This dimensional transition allows the circuit substrate to be accommodated without increasing axial length, effectively solving the miniaturization problem.
2Reliability
If insulation sheets are added between the circuit substrate and other components, then insulation performance improves, but the axial length increases
Solution Approach 1:
The invention employs thin film insulation sheets with high LOI values (20.8% or higher) to provide effective insulation between the circuit substrate and other components. These thin films maintain excellent insulation performance while occupying minimal axial space, thus improving reliability without compromising miniaturization.
Solution Approach 2:
The invention changes the material parameter of the insulation sheet by selecting materials with high LOI values (20.8% or higher), which provide superior insulation performance. This parameter optimization allows for thinner insulation layers, reducing axial length while maintaining or improving insulation reliability.
3Ease of manufacture
If resin is used to fill gaps and integrate components, then manufacturing efficiency improves, but heat dissipation becomes more difficult
Solution Approach 1:
The invention applies resin selectively to fill specific gaps between components for integration and insulation, while maintaining thermal pathways for heat dissipation. This localized application of resin provides manufacturing efficiency without completely blocking heat flow paths, balancing assembly ease with thermal management.
Solution Approach 2:
The invention employs composite material structures where resin is combined with other materials that have good thermal conductivity. This composite approach allows the resin to provide integration and insulation benefits while the thermally conductive components ensure effective heat dissipation, resolving the contradiction between ease of manufacture and temperature control.
Data Source
AI summary
A dynamo-electric machine includes a stator, a rotor disposed in the stator, a bottomed tubular case that accommodates the stator, an end cover mounted on an open end of the case, and a circuit substrate that controls driving of the dynamo-electric machine. The stator includes a core having portions that protrude toward a center of the stator, insulators mounted on the stator core, and a coil wound around each of the protruding portions with the insulators therebetween. The circuit substrate is disposed inward of an outer end of the case and is disposed between the stator and the end cover, and includes a first insulation sheet disposed between the circuit substrate and the stator to insulate the circuit substrate and the coil; and a second insulation sheet disposed between the circuit substrate and the end cover to insulate the circuit substrate and the end cover.