Secondary Circuit Board Sensor Positioning for Motor Assembly
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Solution Overview
Problem
The complexity of packaging and electrical connection of sensors in motor assemblies, which requires additional sensor magnets and increased component count, complicates the design and increases costs.
Innovation Solution
A circuit board assembly with a primary and secondary circuit board, where the secondary board positions sensors in proximity to magnets, reducing the number of components needed and simplifying the electrical connection process through a pick and place assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are mounted to a frame or housing to position them in proximity with sensor magnets, then the sensors can detect the position of the drive shaft, but the packaging and electrical connection of the sensors becomes more complex
Solution Approach 1:
The patent merges the sensor mounting function with the circuit board by directly disposing sensors on the circuit board. This eliminates the need for separate frame or housing mounting structures, thereby reducing packaging complexity while maintaining the sensors' ability to detect drive shaft position through proximity with sensor magnets.
Solution Approach 2:
The circuit board is given multiple functions: it serves as both the electrical connection medium and the mounting platform for sensors. This multi-functionality eliminates the need for dedicated sensor mounting structures, reducing overall device complexity while preserving measurement capabilities.
2Measurement precision
If sensor magnets are added separately from motor magnets, then the sensors can detect drive shaft position, but the number of components increases
Solution Approach 1:
The patent combines sensor magnets with motor magnets into a single integrated component. This merging reduces the total number of components while maintaining the sensor magnets' ability to enable position detection, as the integrated magnets serve both motor function and sensing reference function.
3Ease of manufacture
If a secondary circuit board is introduced to position sensors, then electrical connection is simplified, but device complexity increases
Solution Approach 1:
The patent merges the sensor positioning function with the primary circuit board by directly disposing sensors on it. This eliminates the need for a separate secondary circuit board, thereby simplifying the overall circuit board structure while maintaining ease of manufacture through direct mounting and electrical connection.
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 reduces the complexity of sensor placement and electrical connection, increases throughput, and decreases the number of components required, enhancing the motor assembly's efficiency and profitability.
Implementation Method 1
The sensor magnets are in proximity of the sensors, to allow the sensors to detect the position of the sensor magnets as they rotate with the drive shaft
Data Source
AI summary
A circuit board assembly includes a primary circuit board extending in a first plane and configured to control electrical distribution and a secondary circuit board extending in a second plane, different from the first plane, with the primary and secondary circuit boards spaced from and substantially parallel with one another, and with the secondary circuit board abutting the primary circuit board such that the primary and secondary circuit boards are electrically coupled to one another. The circuit board assembly further includes at least one sensor disposed on the secondary circuit board and electrically coupled to the secondary circuit board such that the at least one sensor is electrically coupled to the primary circuit board through the secondary circuit board, with the secondary circuit board positioning the at least one sensor in proximity with the at least one magnet for detecting the position of the at least one magnet.