PCB Winding Connector Layout for Low-Loss Motor Phase Connections
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Solution Overview
Problem
Conventional methods struggle to provide low-resistance connections between windings and external components in high power density motors and drives, leading to increased losses and fault propagation risks, especially in fault-tolerant machines.
Innovation Solution
Utilizing a printed circuit board (PCB) with heavy copper traces to segment and electrically connect windings, eliminating the need for physical overlap and enabling precise conductor positioning for improved isolation and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or brazing is used to connect windings, then electrical connection is achieved, but resistance increases and losses are introduced
Solution Approach 1:
The patent replaces thermal joining methods (soldering/brazing) with mechanical compression connections using PCB-mounted connectors. The connectors use compression force to establish electrical contact without heat-affected zones, maintaining low resistance connections while avoiding the energy losses associated with thermal joining processes.
Solution Approach 2:
The patent introduces PCB-mounted connectors as intermediary components between windings and external components. These connectors provide low-resistance electrical pathways through compression contacts, serving as mediators that eliminate the need for high-resistance soldering or brazing joints while maintaining reliable electrical connection.
2Loss of energy
If multi-strand wires are used, then eddy current losses are reduced, but connection complexity increases
Solution Approach 1:
The PCB-mounted connectors serve as intermediaries that simplify the connection of multi-strand wires. The connectors are designed to accommodate multiple strands simultaneously through compression contacts, reducing the complexity of connecting each strand individually while preserving the low eddy current losses benefits of multi-strand construction.
Solution Approach 2:
The patent merges multiple wire strands into a single compression contact point on the PCB connector. This combining approach maintains the electrical benefits of multi-strand construction (reduced eddy currents) while simplifying the connection process by treating multiple strands as a unified connection entity rather than requiring individual connections for each strand.
3Reliability
If leads are passed over end-windings for connection, then electrical connection is achieved, but bulk increases and insulation requirements increase
Solution Approach 1:
The patent extracts the connection function from the winding structure itself and relocates it to separate PCB-mounted connectors. This separation eliminates the need for leads to pass over end-windings, removing the associated bulk and insulation requirements while maintaining reliable electrical connections through dedicated connector components.
Solution Approach 2:
The patent transitions from three-dimensional lead routing over end-windings to a two-dimensional PCB surface mount connection. By moving connections to the PCB plane rather than requiring spatial routing through the motor structure, the design eliminates the bulk associated with end-winding passages and simplifies the overall system geometry.
4Ease of manufacture
If conventional connection methods are used, then connections are achieved, but fault propagation risk increases
Solution Approach 1:
The patent segments the electrical connection system into isolated PCB-mounted connector points rather than continuous lead routing. This segmentation creates electrical isolation between different connection points, preventing fault propagation along connection paths while maintaining manufacturing ease through standardized PCB mounting procedures.
Solution Approach 2:
The PCB-mounted connectors act as intermediary isolation points that break potential fault propagation paths. By introducing these discrete connector components between windings and external components, the system achieves fault tolerance through electrical isolation while maintaining ease of manufacture through standardized connector designs and PCB assembly processes.
Data Source
AI summary
A connection assembly for providing electrical connection of a multi-strand wire conductor to another component, comprising a printed circuit board, PCB, whereby the conductor can be connected to a conductive segment or track of the PCB which is also connected to the other component.