Description:FIELD
[0001] The present disclosure relates, in general, to the field of motor control systems.
[0002] More particularly, embodiments of the present disclosure relate to a Brushless Direct Current (BLDC) motor drive assembly and a method thereof.
DEFINITION
[0001] As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
[0002] The term “Printed Circuit Board Assembly (PCBA)” refers to a circuit board that houses both the controller section and the power supply section for operating a BLDC motor.
[0003] The term “Controller Section” refers to a segment of the PCBA responsible for processing control signals and regulating power delivery to the BLDC motor.
[0004] The term “Power Supply Section” refers to a segment of the PCBA that supplies electrical power to the controller section and the BLDC motor.
[0005] The term “Detachable Connector Assembly” refers to a modular interface that enables electrical and mechanical coupling between the controller section and the power supply section, allowing for easy disconnection and replacement of faulty components.
[0006] The term “Berg Stick Connector” refers to an 4-pin male or female connector used to establish electrical contact between the controller section and power supply section.
BACKGROUND
[0007] The background information herein below relates to the present disclosure but is not necessarily prior art.
[0008] The Brushless Direct Current (BLDC) motors are widely used in various industrial and consumer applications due to their high efficiency, precise control, and durability. However, traditional PCBA designs suffer from several limitations related to repairability and waste generation.
[0009] Electronic waste (e-waste) has become a significant environmental challenge, as defective PCBAs are often discarded entirely rather than repaired. Service centers and manufacturers face high costs due to the need for full board replacements, leading to greater inventory demands and higher costs for consumers.
[0010] The power supply section is the most common failure point in BLDC motor drive assemblies, yet current designs do not allow for targeted repairs. Instead, the entire PCBA is replaced, leading to increased repair costs, environmental concerns, and inefficient serviceability.
[0011] Non-modular PCB designs also complicate in-field repairs, making it difficult for technicians to replace only the faulty components. This results in longer downtime, supply chain inefficiencies, and increased production waste.
[0012] Therefore, there is felt a need for a Brushless Direct Current (BLDC) motor drive assembly and a method thereof, that alleviates the aforementioned drawbacks.
OBJECTS
[0013] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
[0014] It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
[0015] The main object of the present disclosure is to provide a Brushless Direct Current (BLDC) motor drive assembly and a method thereof.
[0016] Another object of the present disclosure is to provide a BLDC motor drive assembly that improves repairability and serviceability by enabling the replacement of individual components instead of the entire PCBA.
[0017] Another object of the present disclosure is to provide a BLDC motor drive assembly with a detachable connector assembly, allowing modular replacement of the power supply section while retaining the controller section.
[0018] Another object of the present disclosure is to provide a BLDC motor drive assembly that enables on-site repairs, thereby minimizing downtime and improving maintenance efficiency.
[0019] Another object of the present disclosure is to provide a BLDC motor drive assembly that is cost-effective and reduces electronic waste by eliminating unnecessary full board replacements.
[0020] Another object of the present disclosure is to provide a BLDC motor drive assembly with a specialized Berg Stick connector system, ensuring seamless electrical connectivity while allowing for modular disassembly and reassembly.
[0021] Another object of the present disclosure is to provide a BLDC motor drive assembly that enhances supply chain efficiency by reducing the need for stocking entire PCBAs, allowing service centers to store only power supply sections for quick replacements.
[0022] Another object of the present disclosure is to provide a BLDC motor drive assembly that is scalable and applicable to various home appliances, industrial fans, and other motor-driven systems.
[0023] Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.
SUMMARY
[0024] This summary is provided to introduce concepts related to a Brushless Direct Current (BLDC) motor drive assembly. The concepts are further described below in the following detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[0025] The present disclosure envisages a Brushless Direct Current (BLDC) motor drive assembly. The Brushless Direct Current (BLDC) motor drive assembly comprises a Printed Circuit Board Assembly (PCBA), and a detachable connector assembly. The Printed Circuit Board Assembly (PCBA) includes a controller section and a power supply section. The controller section is configured to process control signals for operating a BLDC motor. The power supply section is configured to supply power to the controller section and the BLDC motor. The detachable connector assembly is configured to electrically and mechanically couple the controller section and the power supply section. The detachable connector assembly comprises a female connector that is removably attachable to a corresponding male connector disposed on the PCBA in an inverted position of the detachable connector assembly.
[0026] In an embodiment, the detachable connector assembly comprises at least two 4-pin Berg Sticks to facilitate electrical connectivity between the controller section and the power supply section.
[0027] In an embodiment, the male connector, after being removed, is reinserted in the inverted position of the detachable connector assembly, for ensuring reusability and alignment of the electrical contacts between the female connector and the controller section.
[0028] In an embodiment, the controller section includes a microcontroller programmed to regulate power delivery to the BLDC motor based on received input signals.
[0029] In an embodiment, the power supply section is configured to provide a variable voltage output based on the operating conditions of the BLDC motor.
[0030] In an embodiment, the PCBA is fabricated using a sustainable manufacturing process to further minimize environmental impact.
[0031] In an embodiment, the detachable connector assembly enables a modular replacement system, thereby reducing inventory costs for service centers by requiring storage of only power supply sections rather than entire PCBAs.
[0032] In an embodiment, the PCBA is fabricated using FR4 double-sided printed circuit board material, ensuring thermal and electrical stability.
[0033] In an embodiment, the power supply section comprises a transformer, electrolytic capacitors, bridge rectifiers, diodes, and a power management integrated circuit (IC). The transformer converts AC voltage to a lower DC voltage. The electrolytic capacitors for filtering DC voltage post-rectification. The bridge rectifiers and diodes for converting AC to DC power. The power management integrated circuit (IC) for regulating power flow.
[0034] The present disclosure further envisages a method for servicing a brushless DC (BLDC) motor drive assembly. The method includes the following steps:
• detecting a failure in a power supply section of a PCBA;
• removing a female connector of a detachable connector assembly from a male connector disposed on the PCBA;
• detaching the power supply section from a controller section without affecting the operation of the controller section;
• replacing the power supply section with a new or refurbished power supply section;
• reattaching the female connector of the detachable connector assembly in the male connector disposed on the PCBA, thereby restoring the electrical connection between the controller section and the power supply section; and
• testing the restored BLDC motor drive assembly to verify operational integrity.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
[0035] A Brushless Direct Current (BLDC) motor drive assembly and a method thereof, of the present disclosure will now be described with the help of the accompanying drawing, in which:
[0036] Figure 1 illustrates a Brushless Direct Current (BLDC) motor drive assembly, in accordance with an embodiment of the present disclosure;
[0037] Figures 2A, 2B, & 2C illustrate the different views of the female connector of the Brushless Direct Current (BLDC) motor drive assembly, in accordance with an embodiment of the present disclosure;
[0038] Figure 3 illustrates the two Berg Sticks of the Brushless Direct Current (BLDC) motor drive assembly, in accordance with an embodiment of the present disclosure;
[0039] Figure 4 illustrates the detachable connector assembly of the Brushless Direct Current (BLDC) motor drive assembly, in accordance with an embodiment of the present disclosure;
[0040] Figures 5A, 5B, 5C, 5D, 5E, 5F, & 5G illustrate the progression from the initial stage to the final stage of the Brushless Direct Current (BLDC) motor drive assembly, in accordance with an embodiment of the present disclosure; and
[0041] Figures 6A & 6B illustrate a method for servicing a brushless DC (BLDC) motor drive assembly, in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS USED IN THE DESCRIPTION AND DRAWING:
100 assembly
600 method
110 Printed Circuit Board Assembly (PCBA)
120 controller section
130 power supply section
130A transformer
130B electrolytic capacitors
130C bridge rectifiers and diodes
130D power management integrated circuit (IC)
140 detachable connector assembly
150 female connector
160 male connector
170, 180 two 4-pin Berg Sticks (4 to 20 pin possibility)
190 microcontroller

DETAILED DESCRIPTION
[0042] Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
[0043] Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components and methods to provide a complete understanding of the embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known apparatus structures, and well-known techniques are not described in detail.
[0044] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an”, and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms, “comprises”, “comprising”, “including” and “having” are open-ended transitional phrases and therefore, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0045] When an element is referred to as being “embodied thereon”, “engaged to”, “coupled to” or “communicatively coupled to” another element, it may be directly on, engaged, connected, or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
[0046] The Brushless Direct Current (BLDC) motors are widely used in industrial and consumer applications due to their efficiency, precise control, and durability. However, traditional PCBA designs pose challenges in repairability and contribute to electronic waste.
[0047] The power supply section is the most common failure point in BLDC motor drive assemblies, yet conventional designs require full PCBA replacement instead of targeted repairs. This leads to higher costs, increased electronic waste, and inefficiencies in serviceability.
[0048] Non-modular PCBs further requires complete motor disassembly for PCB replacement and uses screw terminals or fixed soldered joints which complicate repairs, resulting in longer downtime, and supply chain inefficiencies.
[0049] Therefore, there is a need for a Brushless Direct Current (BLDC) motor drive assembly and a method thereof that enables independent repairability or plug and play maintenance, reduces electronic waste, and improves cost-effective serviceability.
[0050] The present disclosure envisages a Brushless Direct Current (BLDC) motor drive assembly and a method thereof. The Brushless Direct Current (BLDC) motor drive assembly 100 is described with reference to Figures 1 to 5F, in accordance with the present disclosure. The method 600 for servicing a brushless DC (BLDC) motor drive assembly 100 is described with reference to Figures 6A & 6B, in accordance with the present disclosure.
[0051] Figure 1 to 4 illustrates the Brushless Direct Current (BLDC) motor drive assembly 100, in accordance with an embodiment of the present disclosure. The Brushless Direct Current (BLDC) motor drive assembly 100 comprises a Printed Circuit Board Assembly (PCBA) 110, and a detachable connector assembly 140. The Printed Circuit Board Assembly (PCBA) 110 includes a controller section 120 and a power supply section 130. The controller section 120 is configured to process control signals for operating a BLDC motor. The power supply section 130 is configured to supply power to the controller section 120 and the BLDC motor. The detachable connector assembly 140 is configured to electrically and mechanically couple the controller section 120 and the power supply section 130. The detachable connector assembly 140 comprises a female connector 150, as can be seen in Figures 2A, 2B, & 2C. The female connector 150 is removably attachable to a corresponding male connector 160 disposed on the PCBA 100 in an inverted position of the detachable connector assembly 140, as can be seen in Figure 3. The female connector has at least 16-Pin.
[0052] In an embodiment, the detachable connector assembly 140 comprises at least two 2-pin Berg Sticks 170, 180 to facilitate electrical connectivity between the controller section 120 and the power supply section 130, as can be seen in Figure 4. The number of pins in the connector assembly 140 may vary between 4 to 20 based on design requirements.
[0053] In an embodiment, the male connector 160, after being removed, is reinserted in the inverted position of the detachable connector assembly 140, to ensure reusability and alignment of the electrical contacts between the female connector 150 and the controller section 120.
[0054] In an embodiment, the controller section 120 includes a microcontroller 190 programmed to regulate power delivery to the BLDC motor based on received input signals.
[0055] In an embodiment, the power supply section 130 is configured to provide a variable voltage output based on the operating conditions of the BLDC motor.
[0056] In an embodiment, the PCBA 110 is fabricated using a sustainable manufacturing process to further minimize environmental impact.
[0057] In an embodiment, the detachable connector assembly 140 enables a modular replacement system, thereby reducing inventory costs for service centers by requiring storage of only power supply sections rather than entire PCBAs.
[0058] In an embodiment, the PCBA 110 is fabricated using FR4 double-sided printed circuit board material, ensuring thermal and electrical stability.
[0059] In an embodiment, the power supply section 130 comprises a transformer 130A, electrolytic capacitors 130B, bridge rectifiers and diodes 130C, and a power management integrated circuit (IC) 130D. The transformer 130A for converting AC voltage to a lower DC voltage. The electrolytic capacitors 130B for filtering DC voltage post-rectification. The bridge rectifiers and diodes 130C for converting AC to DC power. The power management integrated circuit (IC) 130D for regulating power flow.
[0060] In an embodiment, the Berg Sticks 170, 180 are positioned at predefined locations to ensure proper electrical alignment.
[0061] In an embodiment, the detachable connector assembly 140 facilitates the separation of the controller circuit and power circuit for independent assembly and testing.
[0062] In an embodiment, the power supply failure ratio to controller failure ratio is approximately 80:20, making the modular split an optimal solution for reducing repair costs.
[0063] In an embodiment, the male connector 150 is designed for multiple insertions and removals, ensuring durability and long-term usability.
[0064] In an embodiment, the connector-based design can be adapted for varying voltage ratings and motor sizes, making it scalable for different applications.
[0065] In an embodiment, the power circuit section is designed to be separately serviceable, allowing targeted repair or replacement without replacing the entire PCBA.
[0066] In an embodiment, the modular connector assembly enables on-site serviceability, allowing the technician to separate and replace only the faulty circuit section. Thus reducing service time significantly.
[0067] In an embodiment, the PCBA assembly 110 enables miniaturization of the controller, thereby reducing material consumption and improving cost efficiency.
[0068] In an embodiment, the modular design contributes to a 50% reduction in electronic waste, supporting environmental sustainability initiatives.
[0069] In an embodiment, the detachable connector assembly 110 is adaptable for various electronic appliances, including mixers, table fans, industrial fans, cooler fans, and exhaust fans.
[0070] In an embodiment, the connector-based modular structure reduces manufacturing costs and component replacement costs, with an estimated power PCB replacement cost of ₹170 and a BLDC controller PCB replacement cost of ₹185 per unit.
[0071] In an embodiment, the detachable connector assembly 140 supports compliance with sustainability regulations and e-waste reduction mandates.
[0072] Figures 5A, 5B, 5C, 5D, 5E, 5F, & 5G illustrate the progression from the initial stage to the final stage of the Brushless Direct Current (BLDC) motor drive assembly 100, in accordance with an embodiment of the present disclosure. The PCB is designed such that the PCBA (Printed Circuit Board Assembly) 110 exists as a single unit, which can be divided into two distinct sections when serviceability is needed.
[0073] As shown in Figure 5A, the PCB is represented as a single board. Typically, the PCB comprises two parts. One part is the controller section 140 and the other part is the power supply section 130. The controller section 140 is located on the left side of the PCB, while the power supply section 130 is on the right. A 3D view of the PCB after it has been bifurcated is illustrated in Figure 5C & Figure 5D.
[0074] As depicted in Figure 5E, two 4-pin Berg sticks 170, 180 serve as the primary division points for the PCBA 110. This is the point where the PCB splits into two distinct sections. Additionally, both sections of the PCB are connected by the female connector 150. The female connector 150 is removably attachable to a corresponding male connector 160 as can be seen in Figure 5F, which is disposed on the PCBA 100, ensuring modular connectivity between the controller section and the power supply section.
[0075] FIGURE 6A, & 6B illustrate a method 600 for servicing a brushless DC (BLDC) motor drive assembly 100, in accordance with an embodiment of the present disclosure. The order in which the method 600 is described is not intended to be construed as a limitation, and any number of the described method steps can be combined in any appropriate order to carry out the method 600 or an alternative method. Additionally, individual steps may be deleted from the method 600 without departing from the scope of the subject matter described herein. The method 600 for servicing a brushless DC (BLDC) motor drive assembly 100.
[0076] In method step 602, the method 600 comprises detecting 602 a failure in a power supply section 130 of a PCBA 110.
[0077] In method step 604, the method 600 comprises removing 604 a female connector 150 of a detachable connector assembly 140 from a male connector 160 disposed on the PCBA 110.
[0078] In method step 606, the method 600 comprises detaching 606 the power supply section 130 from a controller section 120 without affecting the operation of the controller section 120.
[0079] In method step 608, the method 600 comprises replacing 608 the power supply section 130 with a new or refurbished power supply section.
[0080] In method step 610, the method 600 comprises reattaching 610 the female connector 150 of the detachable connector assembly 140 in the male connector 160 disposed on the PCBA 110, thereby restoring the electrical connection between the controller section 120 and the power supply section 130.
[0081] In method step 612, the method 600 comprises testing 612 the restored BLDC motor drive assembly to verify operational integrity.
[0082] The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but, are interchangeable and cross-compatible. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
[0083] The present disclosure described herein above has several technical advantages including, but not limited to, a Brushless Direct Current (BLDC) motor drive assembly and a method thereof, which:
• eliminates unnecessary PCB waste, optimizing material utilization;
• facilitates supply chain efficiency by reducing inventory costs for serviceable parts;
• allows for standardization across multiple product lines, reducing design complexity;
• enhances production efficiency and simplifies the assembly process;
• enables on-site repairs, thereby minimizing downtime and improving maintenance efficiency;
• reduces electronic waste by eliminating unnecessary full board replacements and is cost-effective;
• ensuring seamless electrical connectivity while allowing for modular disassembly and reassembly; and
• reducing the need for stocking entire PCBAs, allowing service centers to store only power supply sections for quick replacements.
[0084] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0085] The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
[0086] The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
[0087] Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
[0088] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
[0089] While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A Brushless Direct Current (BLDC) motor drive assembly (100), comprising:
o a Printed Circuit Board Assembly (PCBA) (110) including:
 a controller section (120) configured to process control signals for operating a BLDC motor; and
 a power supply section (130) configured to supply power to the controller section (120) and the BLDC motor;
o a detachable connector assembly (140) configured to electrically and mechanically couple the controller section (120) and the power supply section (130); and
o wherein the detachable connector assembly (140) comprises a female connector (150) that is removably attachable to a corresponding male connector (160) disposed on the PCBA (100) in an inverted position of the detachable connector assembly (140).
2. The BLDC motor drive assembly (100) as claimed in claim 1, wherein the detachable connector assembly (140) comprises at least two 4-pin Berg Sticks (170, 180) to facilitate electrical connectivity between the controller section (120) and the power supply section (130).
3. The BLDC motor drive assembly (100) as claimed in claim 1, wherein the male connector (160), after being removed, is reinserted in the inverted position of the detachable connector assembly (140), to ensure reusability and alignment of the electrical contacts between the female connector (150) and the controller section (120).
4. The BLDC motor drive assembly (100) as claimed in claim 1, wherein the controller section (120) includes a microcontroller (190) programmed to regulate power delivery to the BLDC motor based on received input signals.
5. The BLDC motor drive assembly (100) as claimed in claim 1, wherein the power supply section (130) is configured to provide a variable voltage output based on the operating conditions of the BLDC motor.
6. The BLDC motor drive assembly (100) as claimed in claim 1, wherein the PCBA (110) is fabricated using a sustainable manufacturing process to further minimize environmental impact.
7. The BLDC motor drive assembly (100) as claimed in claim 1, wherein the detachable connector assembly (140) enables a modular replacement system, thereby reducing inventory costs for service centers by requiring storage of only power supply sections rather than entire PCBAs.
8. The BLDC motor drive assembly (100) as claimed in claim 1, wherein the PCBA (110) is fabricated using FR4 double-sided printed circuit board material, ensuring thermal and electrical stability.
9. The BLDC motor drive assembly (100) as claimed in claim 1, wherein the power supply section (130) comprises:
o a transformer (130A) for converting AC voltage to a lower DC voltage;
o electrolytic capacitors (130B) for filtering DC voltage post-rectification;
o bridge rectifiers and diodes (130C) for converting AC to DC power; and
o a power management integrated circuit (IC) (130D) for regulating power flow.
10. A method (600) for servicing a brushless DC (BLDC) motor drive assembly b comprising:
• detecting (602) a failure in a power supply section (130) of a PCBA (110);
• removing (604) a female connector (150) of a detachable connector assembly (140) from a male connector (160) disposed on the PCBA (110);
• detaching (606) the power supply section (130) from a controller section (120) without affecting the operation of the controller section (120);
• replacing (608) the power supply section (130) with a new or refurbished power supply section;
• reattaching (610) the female connector (150) of the detachable connector assembly (140) in the male connector (160) disposed on the PCBA (110), thereby restoring the electrical connection between the controller section (120) and the power supply section (130); and
• testing (612) the restored BLDC motor drive assembly to verify operational integrity.

Dated this 01st Day of March 2025

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT NEW DELHI