Programmable PCB Extension for Miniature Motor Programming
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Solution Overview
Problem
The challenge lies in achieving reliable and cost-effective electrical contacting of miniature motors, particularly in the precise alignment of sensor components like encoders with rotor magnets, due to manufacturing tolerances and limited space, which results in inaccurate positioning and misalignment of contact surfaces.
Innovation Solution
A circuit board extension with material weakening areas and double-sided contact surfaces is designed to protrude beyond the motor housing, allowing for easy contact and subsequent separation, enabling precise alignment and automatic or manual contacting via standardized connectors, with a flexible area for tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact surfaces are made large enough for reliable automatic contacting, then contacting reliability is improved, but the available space on the circuit board is reduced, making integration difficult in miniature motors
Solution Approach 1:
The circuit board is divided into a main assembly section and a separate extension section. The extension section carries the contact surfaces and can be detached after programming, allowing large contact surfaces without permanently increasing the integrated circuit board area.
Solution Approach 2:
The extension acts as an intermediary carrier that provides the necessary contact surfaces for programming. It connects the circuit board to the programming device during programming, then can be removed, serving as a temporary mediator that enables reliable contacting without permanent space occupation.
2Volume of stationary object
If contact surfaces are integrated into the housing for miniature motors, then space utilization is improved, but accessibility for programming is reduced in tight spaces
Solution Approach 1:
The extension with contact surfaces is designed to protrude from the housing before programming occurs. This preliminary configuration allows programming access in tight spaces, and only after programming is complete does the extension become unnecessary and can be removed.
Solution Approach 2:
The extension transitions from a protruding state that provides programming accessibility to a removed state that maximizes housing volume utilization. This dynamic change allows the system to optimize for accessibility during programming and for compactness during operation.
3Ease of operation
If the extension protrudes beyond the housing for easy contacting, then contacting ease is improved, but the extension becomes a bothersome component after programming
Solution Approach 1:
The extension is designed as a separable segment that can be easily detached from the main assembly after programming. The material weakening area provides a predetermined separation point that allows clean division between the extension and the permanent assembly, reducing long-term complexity.
Solution Approach 2:
The extension serves its purpose during programming and is then discarded (removed) from the final assembly. This temporary component approach allows the system to benefit from the extension's protruding design during programming while eliminating the complexity burden in the finished product.
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 solution ensures reliable and cost-effective contacting of miniature motors by allowing for precise alignment and easy separation of the contact extension, facilitating automatic or manual programming without damaging components, even in tight spaces.
Implementation Method 1
an extension (8) is formed on the mounting section (6), which extension (8) has the electrical contact surfaces (17) and which is connected to the mounting section (6) via a material weakening area (12)
Implementation Method 2
to compensate for tolerances of the positions between the device, for. B. the drive of the micro motor and a mounting device a flexible area z. B. made of polyimide between the material weakening area and the contact surfaces in the extension according to the invention
Data Source
AI summary
The present invention relates to a programmable electronic assembly comprising a printed circuit board (1) with electrical conductors (1a) and electronic components (5) contacted on the conductors (1a), including a programmable electronic component (4), in particular a sensor component such as an encoder or a motion sensor, as well as electrical contact surfaces (17) connected to the conductors (1a) for contacting contact pins of an external programming unit. The printed circuit board (1) has a mounting section (6) comprising the electronic components (4, 5) and a connection section (7) extending from it, and a projection (8) of the printed circuit board (1) is formed on the mounting section (6), which has the electrical contact surfaces (17) for connecting the contact pins (36) and is connected to the mounting section (6) via a material weakening area (12).