Switching Disc Contact Layout for Multi-Diameter Stator PCBs
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Solution Overview
Problem
Existing electric motor stators with different diameters require separate switching disks and circuit boards, leading to increased production costs due to the need for customized components.
Innovation Solution
A switching disk with a ring-shaped support structure and radially offset contact arrangements, including winding contacts, circuit board contacts, and coupling elements, allows for standardization of circuit boards across different stator diameters by compensating for radial offsets, enabling a single type of circuit board to contact various stator diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate switching disks and circuit boards are provided for each stator diameter, then reliable electrical contact is ensured, but production costs increase due to component customization
Solution Approach 1:
The switching disk is designed with a universal interface that can accommodate multiple stator diameters. The contact arrangements include winding contacts on a first pitch circle diameter and circuit board contacts on a second pitch circle diameter, allowing the same switching disk design to work with different stator sizes while maintaining reliable electrical contact and reducing the need for customized components
2Adaptability or versatility
If circuit board contacts are positioned at the same pitch circle diameter as winding contacts, then a single circuit board type can be used, but radial offset compensation is lost
Solution Approach 1:
The invention resolves the radial offset issue by introducing a dimensional separation between winding contacts and circuit board contacts. The winding contacts are arranged on a first pitch circle diameter while circuit board contacts are arranged on a second pitch circle diameter, allowing both universal compatibility and precise radial positioning through the coupling element's angled configuration
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a switching disk (1) for contacting windings (32) of a stator (2) of an electric motor arranged around an axis of rotation (X) with a printed circuit board of the electric motor, wherein the switching disk (1) has a support structure (10) that runs in a ring around the axis of rotation (X) and several contact arrangements (20) for contacting the windings (32) with the printed circuit board, which are held by the support structure (10), wherein the contact arrangements (20) each consist of a winding contact (21) for contacting one of the windings (20), a printed circuit board contact (23) offset thereto in the radial direction (R) for contacting the printed circuit board, and a coupling element (22) extending in the radial direction (R) and electrically connecting the winding contact (21) with the printed circuit board contact (23).