Segmented Brushless Stator Interconnect via Press-Fit PCB
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Solution Overview
Problem
Current interconnect methods for brushless rotary motors are complex and costly, leading to inefficient assembly and suboptimal copper fill in stator coils, which affects performance and increases production costs.
Innovation Solution
A segmented stator assembly system using a press-fit printed circuit board (PCB) with insulation displacement connectors (IDCs) that allows for uniform winding of coils and eliminates the need for soldering, enabling efficient electrical connections and improved copper fill through bobbin-winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional individual wiring methods are used for stator segments, then each segment can be assembled separately, but the assembly complexity and cost increase significantly
Solution Approach 1:
The stator is divided into multiple independent segments that can be manufactured separately, each with its own coil and interconnect structure. This segmentation allows parallel manufacturing of segments while maintaining electrical connectivity through the interconnect structure, resolving the contradiction between individual segment assembly and overall wiring complexity
Solution Approach 2:
The electrical interconnect structure is integrated directly into the stator segments themselves, merging the function of electrical connection with the structural component. This eliminates separate wiring steps and reduces assembly complexity while maintaining the ability to connect multiple segments electrically
2Quantity of substance
If traditional wiring methods are used for coil terminals, then electrical connections can be made, but copper fill optimization becomes difficult
Solution Approach 1:
The interconnect structure enables optimization of copper fill by changing the electrical connection parameters and configuration. The integrated design allows for better utilization of copper material in the stator segments while simplifying the wiring architecture, directly addressing both copper fill optimization and reduced wiring complexity
3Productivity
If individual wiring is performed for each stator segment, then customization is possible, but production cost and time increase
Solution Approach 1:
By segmenting the stator into modular units with integrated interconnect structures, each segment can be manufactured independently using standardized processes. This enables mass production of individual segments that are then assembled, significantly improving productivity while controlling manufacturing costs through standardization
Solution Approach 2:
The electrical interconnect structure is built into each stator segment during its initial manufacturing process, performing the electrical connection preparation in advance. This preliminary action eliminates the need for complex post-assembly wiring operations, reducing both production time and cost
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
The solution simplifies assembly, reduces labor and costs, enhances motor performance by increasing copper fill, and minimizes quality issues associated with soldering, such as fractured joints, while allowing for greater torque and reduced coil heating.
Implementation Method 1
The spring element may include a pair of resilient arms that are compressible in a direction transverse to the longitudinal axis of the terminal
Implementation Method 2
The coils in the stator segments are energized with current to produce electromagnetic fields. The electromagnetic fields generated in the stator coils interact with the permanent magnets of the rotor to induce torque and rotation of the rotor
Implementation Method 3
The first terminal may include a pair of prongs that are adapted to make incisions into coil terminals to which they are inserted
Data Source
AI summary
A stator of an electric motor is provided. The stator includes a plurality of segments, each of the segments including a tooth having a magnetically-permeable material, an electric coil surrounding the tooth, and at least one insulator. The stator also includes a plurality of connectors, each connector including first and second terminals, the first terminal adapted to be inserted into the at least one insulator and to couple to the electric coil of each of the plurality of segments and a circuit board coupled to input power lines and including apertures adapted to receive the second terminals of the plurality of connectors. The circuit board is coupled to the electric coils of each of the plurality of segments via when the second terminals are received in the apertures.