Modular Axial Motor Assembly With Fixed Magnet-Core Gaps
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Solution Overview
Problem
The assembly of axial motors is complicated due to the need for constant distances between multiple stages of cores and magnets, making expansion and assembly difficult.
Innovation Solution
The axial motor design includes a shaft, stator means with a core and coil, rotor means with magnets and a fixing plate, and detachable lids, allowing for easy assembly and expansion by maintaining consistent distances between magnets and cores using gap stoppers and carriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple stages of cores and magnets are arranged in axial direction, then motor power and torque are improved, but assembly complexity and difficulty increase due to need for constant distances
Solution Approach 1:
The motor is divided into multiple independent stages, each with its own core and magnet assembly. These stages can be manufactured separately and then assembled along the axial direction, allowing complex multi-stage configurations to be built from simpler modular units while maintaining constant distances between components.
Solution Approach 2:
Spacer elements are introduced as intermediary components between the core and magnets to maintain constant distances. These spacers act as mediators that ensure precise spacing without requiring complex adjustment mechanisms during assembly, thereby simplifying the assembly process while maintaining the required geometric relationships.
2Power
If multiple stages of cores and magnets are arranged in axial direction, then motor power and torque are improved, but assembly difficulty increases due to need for constant distances
Solution Approach 1:
The constant distance requirements are pre-established through precisely manufactured spacer elements and定位 features on the core and magnet components. This preliminary preparation of positioning features eliminates the need for complex measurement and adjustment operations during assembly, making the assembly process easier despite the multi-stage configuration.
Solution Approach 2:
Spacer elements serve as intermediaries that encapsulate the distance-maintaining function, converting a complex positioning requirement into a simple insertion operation. The spacers are designed with features that automatically locate and align components, thereby simplifying the assembly operation while ensuring constant distances are maintained.
3Power
If rotor and stator are expanded into multiple stages, then motor performance is improved, but assembly becomes difficult even with expansion
Solution Approach 1:
Both the rotor and stator are segmented into multiple stages that can be independently manufactured and assembled. Each stage contains complete functional elements (core, magnets, windings), allowing the motor to be assembled in a modular fashion that simplifies handling and assembly operations while achieving the desired multi-stage performance.
Solution Approach 2:
Spacer and positioning elements are used as intermediaries to maintain precise relationships between expanded rotor and stator stages. These intermediaries provide built-in alignment and spacing features that guide the assembly process, making the expansion to multiple stages easier to execute while maintaining manufacturing precision.
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
This design facilitates easy assembly and expansion of multi-stage motors by maintaining consistent distances between magnets and cores, simplifying the assembly process and enabling efficient motor configuration.
Implementation Method 1
when a current is supplied to a coil wound around the core, the rotor rotates
Implementation Method 2
magnets of the rotor face each other at certain distances from a core of the shaft
Data Source
AI summary
An axial motor according to the present invention includes: a shaft; a stator means having a stator casing, a core of which both ends are exposed from both ends of the stator casing in an axial direction, and a coil accommodated in the stator casing so as to encompass the core, and having the shaft penetratively inserted therein; a plurality of rotor means having a plurality of magnets spaced certain distances apart in a radial direction of the shaft and arranged in a circumferential direction to face the core exposed from one end of the stator casing in the axial direction of the shaft, and a rotor fixing plate, which fixes the magnets such that one surface of the magnet facing the core is exposed and which is injected to be inserted into the stator means and fixed and coupled so as to be integrally rotatable with the shaft, and being inserted into both ends of the stator means; a top lid into which the shaft is rotatably inserted, and which is coupled to be attachable/detachable to/from the stator casing so that a rotor means located at one end of the shaft is accommodated therein; and a bottom lid into which the shaft is rotatably inserted, and which is coupled to be attachable/detachable to/from the stator casing so that a rotor means located at the other end of the shaft is accommodated therein, wherein, when one end of the rotor means is inserted into the stator means, facing surfaces of the magnets and the core are located at certain distances.