Sensor Positioning in Motor Lead Frame Using Cover Member
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Solution Overview
Problem
Conventional dynamoelectric machines, such as brushless DC motors, face challenges in accurately positioning sensors like temperature sensors to ensure precise motor control and heat management, as existing methods do not effectively protect sensors from excessive heat during assembly and may result in inaccurate positioning leading to variations in sensor output.
Innovation Solution
A method for positioning a sensor, such as a temperature sensor, within a dynamoelectric machine using a deformable structure supported by wire leads and a cover member that moves the sensor closer to an outwardly facing surface of a lead frame, with a thermally conductive gap-filling material to facilitate heat transfer and precise positioning, ensuring the sensor is within a predetermined distance for accurate sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is positioned close to the lead frame during assembly, then accurate temperature sensing is achieved, but the sensor is exposed to excessive heat that may damage it
Solution Approach 1:
The sensor is pre-positioned at a first position spaced from the lead frame before the cover member is attached. This preliminary positioning allows the sensor to be in its final accurate location before heat-generating components are assembled, preventing heat damage while ensuring measurement accuracy
Solution Approach 2:
The assembly process is divided into sequential steps: first positioning the sensor at a safe distance, then attaching the cover member to establish the final sensing position. This segmentation separates the sensor placement from heat-generating operations, protecting the sensor while achieving accurate positioning
2Reliability
If the sensor is positioned away from the lead frame to protect it from heat, then sensor safety is improved, but positioning accuracy and sensing precision deteriorate
Solution Approach 1:
The sensor is preliminarily positioned at a safe distance from the lead frame during assembly, then the cover member is attached to bring the sensor to its final accurate sensing position. This ensures the sensor is protected during assembly while achieving precise positioning for accurate temperature sensing
Solution Approach 2:
The cover member acts as an intermediary that establishes the final sensor position. It is attached to the lead frame and positions the sensor at the correct sensing location, mediating between the need for sensor protection during assembly and the requirement for accurate positioning in the final configuration
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 method ensures accurate and protected sensor placement, reducing the risk of damage from heat during assembly and maintaining precise sensor positioning, thereby enhancing motor control and reliability by maintaining the sensor within a predetermined distance from the heat source for consistent temperature sensing.
Implementation Method 1
a thermally conductive gap-filling material to facilitate heat transfer
Data Source
AI summary
A method for positioning a temperature sensor in association with a heat conductive surface in a lead frame located at an end of a dynamoelectric machine. The sensor is supported to the lead frame by lead wires to position the sensor at a first position spaced from an outwardly facing surface defined on the outer side of the lead frame. A cover member is moved to an attachment location in engagement with an outer side of the lead frame, wherein at least a final portion of the movement of the cover member includes positioning an engagement surface of the cover member into engagement with the sensor and causing the sensor to move closer to the outwardly facing surface to a location defining a second position for the sensor.