Electric Supercharger Stator Termination Layout
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Solution Overview
Problem
The complex tracking arrangement in electric supercharger stator assemblies increases costs and results in a thick control module due to multiple layers of PCB, which can interfere with surrounding components.
Innovation Solution
Arranging the input and output terminations of each pair of windings adjacent to each other allows for direct connection without complex tracking, with wires replacing the need for extensive tracking, facilitating a more straightforward and compact control module design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If complex tracking arrangement with multiple PCB layers is used to connect windings to control module, then electrical connections are established, but control module thickness increases and cost increases
Solution Approach 1:
The patent extracts the terminations from their traditional positions directly above each winding and relocates them to the periphery of the stator assembly. This extraction allows the removal of complex multi-layer PCB tracking structures, replacing them with simple wire connections from the peripheral terminations to the control module, thereby reducing both complexity and thickness.
Solution Approach 2:
The patent changes the spatial arrangement of terminations from a vertical arrangement (directly above windings requiring vertical PCB layers) to a peripheral arrangement (around the circumference of the stator). This dimensional change allows connections to be made in a different spatial plane, eliminating the need for stacked PCB layers and reducing control module thickness.
2Device complexity
If complex tracking arrangement with multiple PCB layers is used to connect windings to control module, then electrical connections are established, but manufacturing cost increases
Solution Approach 1:
By extracting terminations from the winding area and placing them peripherally, the patent eliminates the need for expensive multi-layer PCB tracking structures. The simplified connection method using wires instead of complex PCB traces reduces manufacturing costs while maintaining electrical connectivity.
Solution Approach 2:
The patent replaces expensive, complex multi-layer PCB tracking with simpler, cheaper wire connections. While wires may require periodic replacement, the initial manufacturing cost is significantly reduced compared to multi-layer PCB structures, aligning with the principle of using cost-effective components.
3Ease of operation
If terminations are arranged directly above each winding in a ring configuration, then electrical connections are straightforward, but complex tracking layers are required increasing thickness
Solution Approach 1:
The patent transitions the termination arrangement from a vertical dimension (above windings requiring vertical PCB layers) to a peripheral dimension (circumferential arrangement). This allows electrical connections to be made horizontally from the periphery rather than vertically through multiple layers, reducing thickness while maintaining connection simplicity.
Solution Approach 2:
The patent introduces peripheral positioning as an intermediary arrangement that simplifies the connection path. Instead of direct vertical connections requiring PCB layers, the peripheral termination positions act as intermediaries that enable simpler wire-based connections to the control module.
Data Source
AI summary
An electric supercharger comprises a motor, for example a switched reluctance motor. The motor includes a stator assembly (101) comprising a plurality of pairs of windings (103A-C), each pair of windings (103A-C) comprising a first winding for forming a first pole and a second winding for forming a second, opposite, pole, each winding having an input termination (105) and an output termination (107). The terminations (105, 107) of each pair of windings (103A-C) are arranged such that the input terminations (105) for the first and second windings are located adjacent one another and the output terminations (107) of the first and second windings are located adjacent one another.