Universal Sensor PCB for Electric Machine Rotor Position Detection
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Solution Overview
Problem
Existing electric machines require different circuit boards or structural changes to accommodate sensors for varying pilot angles, increasing production costs and complexity, especially when designed for operation in both directions of rotation.
Innovation Solution
An electric machine design that allows for flexible sensor arrangement on a single circuit board using interchangeable fastening means and receptacles, enabling different angle offsets without altering the board's structure, allowing for adjustable pilot angles and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different circuit boards are used to accommodate sensors for varying pilot angles, then the electric machine can achieve different angle offsets, but the production cost and device complexity increase
Solution Approach 1:
A single circuit board is designed with multiple receptacles that can accommodate sensors in different angular positions. The circuit board itself is made universal by incorporating all necessary conductor tracks and connection points for various sensor arrangements, eliminating the need for multiple specialized circuit boards while maintaining adaptability for different pilot angles
Solution Approach 2:
The circuit board is segmented into multiple receptacle positions, each capable of holding a sensor at a specific angle offset. This segmentation allows the sensor to be positioned at different locations on the same board, providing angular variability without requiring different board designs
2Adaptability or versatility
If different circuit boards are used to accommodate sensors for varying pilot angles, then the electric machine can achieve different angle offsets, but the production cost increases
Solution Approach 1:
By designing a universal circuit board that can accommodate multiple sensor positions, the manufacturing process is simplified. Only one type of circuit board needs to be produced in volume, reducing tooling costs, assembly variations, and inventory requirements compared to producing multiple specialized board types
Solution Approach 2:
The system allows dynamic reconfiguration of sensor position on the same circuit board through interchangeable fastening means. This dynamic adaptability enables the same hardware platform to serve multiple configuration needs, reducing overall system cost
3Adaptability or versatility
If structural changes are made to accommodate different sensor arrangements, then the pilot angle can be adjusted, but the device complexity and production variability increase
Solution Approach 1:
The circuit board incorporates multiple receptacles at different angular positions, allowing the sensor to be dynamically repositioned without structural modifications. The fastening means enable easy installation and removal of sensors at different receptacle locations, providing pilot angle adjustability through reconfiguration rather than structural change
Solution Approach 2:
All possible sensor positions are pre-planned and built into the circuit board design during manufacturing. The receptacles and conductor tracks for multiple angular positions are prepared in advance, allowing flexible sensor placement without requiring any structural modifications when the sensor needs to be repositioned
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
Enables cost-effective production of electric machines that can operate in one or two directions of rotation by allowing sensor positions to be adjusted without structural changes, minimizing variability costs and maintaining performance across different configurations.
Implementation Method 1
Magnetic measuring principles are frequently used, wherein the transmitter wheel is embodied with a magnetic ring and the sensors can be embodied as Hall sensors, GMR sensors and the like
Implementation Method 2
the sensors can be embodied as Hall sensors
Data Source
AI summary
An electric machine includes a stator, a rotor, a printed circuit board having at least one sensor configured to detect a position of the rotor, and a system configured to arrange the at least one sensor in different positions on the stator relative to the stator.