Switching Disk Contact Layout for Multi-Diameter Stator PCBs
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Solution Overview
Problem
Existing electric motors require separate switching disks and printed circuit boards for each stator diameter, leading to increased production costs due to the need for customized components despite shared electronics.
Innovation Solution
A switching disk with an annular support structure and multiple contact arrangements, including winding contacts, printed circuit board contacts, and coupling elements, allows a standardized printed circuit board to be used across different stator diameters by compensating for radial offsets through angled designs and detachable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate switching disks and printed circuit boards are provided for each stator diameter, then proper electrical contacting is achieved, but production costs increase due to customized components
Solution Approach 1:
The switching disk is designed with a universal support structure that can accommodate multiple printed circuit board types with different pitch diameters. The support structure includes multiple contact arrangements with coupling elements that can adapt to different stator diameters, allowing a single switching disk design to serve multiple stator types rather than requiring customized switching disks for each stator diameter.
Solution Approach 2:
The contact arrangements are divided into separate components: a printed circuit board contact, a coupling element, and a winding contact. This segmentation allows each component to be independently positioned and adjusted. The coupling element acts as an intermediary that can compensate for radial offsets between the printed circuit board contact and the winding contact, enabling adaptation to different stator diameters while maintaining proper electrical contacting.
2Reliability
If customized printed circuit boards are provided for each stator type, then proper contacting is achieved, but device complexity increases due to multiple component types
Solution Approach 1:
A single universal printed circuit board design can be used with multiple stator types by combining it with the adaptable switching disk. The support structure on the switching disk provides the necessary adaptation capability, eliminating the need to create customized printed circuit boards for each stator diameter and thereby reducing device complexity.
Solution Approach 2:
The coupling element serves as an intermediary component that bridges the gap between the standardized printed circuit board contact and the winding contact. It compensates for radial offsets and enables proper electrical connection without requiring customization of the printed circuit board itself, thus maintaining contacting accuracy while reducing component variety.
3Reliability
If contact arrangements are positioned at different radial distances for different stators, then proper contacting is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The support structure is designed to be adaptable rather than rigidly fixed for a single pitch diameter. It can accommodate printed circuit boards with different pitch diameters by allowing the contact arrangements to be positioned at different radial distances as needed. This dynamic adaptability reduces the need for extremely high manufacturing precision for each specific stator type, as the structure can adjust to accommodate variations.
Solution Approach 2:
The radial distance of the contact arrangements can be changed to match different stator types. The support structure allows for parameter changes in the positioning of contact arrangements, enabling the same switching disk design to work with multiple stator diameters without requiring extremely tight manufacturing tolerances for each specific configuration.
Data Source
AI summary
A switching disk for contacting windings of a stator of an electric motor, which windings are arranged around an axis of rotation, with a printed circuit board of the electric motor, wherein the switching disk has an annular support structure circumferentially extending around the axis of rotation and multiple contact arrangements for contacting the windings with the printed circuit board, which are held by the support structure. The contact arrangements are each formed by a winding contact for contacting one of the windings, a printed circuit board contact offset therefrom in the radial direction for contacting the printed circuit board, and a coupling element extending in the radial direction and electrically connecting the winding contact to the printed circuit board contact.