Brushless Motor Substrate Arrangement for Torque and Heat
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Solution Overview
Problem
Existing electric power tools with integrated motor and circuit configurations face challenges in achieving high torque output and extended continuous running time.
Innovation Solution
A brushless motor design featuring a rotor with a rotational shaft, a stator coil, a first substrate mounting sensor elements to detect the rotor's position, and a second substrate mounting switching elements to control current flow based on sensor detection, with the substrates arranged side by side and intersecting at right angles with the rotational shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If switching elements, position detection elements, and other circuit components are integrated together on an inverter circuit board, then device complexity is reduced, but torque output and continuous running time cannot be further extended
Solution Approach 1:
The patent divides the circuit components into separate functional modules: the sensor element is mounted on a first substrate while the switching element is mounted on a second substrate. This segmentation allows each component to be optimized independently, enabling higher torque output and extended continuous running time while maintaining manageable device complexity through modular architecture.
2Device complexity
If sensor elements and switching elements are integrated on the same substrate, then device complexity is reduced, but heat dissipation and position detection accuracy are compromised
Solution Approach 1:
The patent separates the sensor element and switching element onto different substrates (first substrate and second substrate respectively). This physical separation allows the switching element to be positioned in a region with better heat dissipation conditions, while the sensor element maintains its position detection accuracy without being affected by thermal interference from the switching element.
3Volume of moving object
If circuit components are closely integrated, then device size is reduced, but heat dissipation and component adjustment flexibility are limited
Solution Approach 1:
The patent arranges the first substrate and second substrate side by side in a planar configuration, with their surfaces extending in different directions relative to the rotational shaft. This spatial arrangement in multiple dimensions allows the motor to maintain a compact overall size while providing adequate separation between the sensor element and switching element for effective heat dissipation and independent position adjustment.
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 configuration enables high-torque output and extended continuous running time while reducing the motor's overall size and improving heat dissipation, allowing for accurate position detection and independent adjustment of sensor and switching element positions.
Implementation Method 1
a sensor element (410) mounted on a first substrate (41) and configured to detect a rotational position of the rotor (2)
Implementation Method 2
a switching element (425) mounted on a second substrate (42) and configured to change, based on a result of detection by the sensor element (410), a conducting direction in which a current flows with respect to the coil (31)
Data Source
AI summary
A motor for electric power tools according to an embodiment includes: a rotor having a rotational shaft; a stator having a coil to rotate the rotor; a first substrate mounting a sensor element to detect a rotational position of the rotor; and a second substrate mounting a switching element to change, based on a result of detection by the sensor element, a conducting direction in which a current flows with respect to the coil. The first substrate and the second substrate are arranged side by side along, and intersect at right angles with, the rotational shaft.