Parallel PCB Mounting for EC Motor Sensor Precision
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Solution Overview
Problem
Conventional power machine tools with electronically commutated drive motors face challenges in accurately aligning printed circuit boards with rotational-direction sensors and temperature sensors, affecting the precision of rotational-direction signals and temperature measurements, which can lead to reduced motor and tool lifetime.
Innovation Solution
The solution involves a printed circuit board aligned parallel to the motor shaft, secured to an insulating body with a stabilizing element, featuring rotational-direction sensors and a contact element for precise signal transmission, and a temperature sensor positioned for accurate temperature measurement, ensuring reliable and sturdy mounting and interference-free signal acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the printed circuit board is mounted perpendicular to the motor shaft axis, then the mounting structure is simple, but the rotational-direction signal precision deteriorates
Solution Approach 1:
The printed circuit board is rotated from a perpendicular mounting orientation to a parallel orientation relative to the motor shaft axis. This dimensional change in mounting configuration allows the rotational-direction sensor to face the motor shaft directly, thereby improving rotational-direction signal precision while maintaining structural simplicity through the stabilizing element.
2Measurement precision
If the printed circuit board is aligned parallel to the motor shaft, then the rotational-direction signal precision improves, but the mounting stability deteriorates
Solution Approach 1:
A stabilizing element is introduced as an intermediary component between the printed circuit board and the insulating body. This stabilizing element provides mechanical support and positioning features that ensure the printed circuit board remains stable and correctly positioned in its parallel alignment configuration, thereby maintaining both mounting stability and sensor precision.
3Measurement precision
If the printed circuit board is mounted with precise alignment, then the sensor measurement precision improves, but the manufacturing complexity increases
Solution Approach 1:
The stabilizing element incorporates pre-formed positioning features and alignment structures that guide the printed circuit board into the correct parallel alignment during assembly. This preliminary preparation of alignment features eliminates the need for complex precision alignment procedures during manufacturing, thereby maintaining high sensor measurement precision while simplifying the manufacturing process.
4Reliability
If the printed circuit board is secured firmly to the insulating body, then the mounting reliability improves, but the sensor signal quality deteriorates due to interference
Solution Approach 1:
The stabilizing element provides localized mechanical securing at specific mounting points that are strategically positioned away from the sensor areas. This localized fixation approach ensures firm mounting reliability for the printed circuit board while maintaining clear, interference-free signal paths between the sensors and their respective targets (motor shaft and motor winding).
Data Source
AI summary
In a power machine tool which has an electronically commutated drive motor that has a motor shaft and to which a stator core is assigned that s provided at least sectionally with an insulating body at one axial end, with a printed circuit board being disposed in the area of the insulating body and being provided with at least one rotational-direction sensor and at least one temperature sensor as well as a contact element for the electrical contacting of the at least one rotational-direction sensor and the at least one temperature sensor, the printed circuit board is aligned at least sectionally parallel to the motor shaft, and is disposed on the insulating body in such a way that the at least one rotational-direction sensor faces the motor shaft.