Axial Air-Gap Motor Stator Assembly with Hook and Locking Shaft
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of axial air-gap electronic motors is labor-intensive and time-consuming due to the temporary nature of core member connections and the complexity of wire connections in existing stator configurations.
Innovation Solution
The stator core members are connected using a bobbin-shaped configuration with insulators featuring hook and locking mechanisms, along with guide and holding portions, to ensure secure and efficient assembly, and terminal pins facilitate easy coil connection, reducing labor and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If core members are assembled by fitting concave portions on bosses temporarily for molding, then the stator can be formed easily, but the core members are easily disconnected by slight shock and require much time and labor for wire connection
Solution Approach 1:
The stator is divided into multiple independent core members that can be manufactured separately and then connected through the resin compact. Each core member maintains its structural integrity while allowing for simplified individual manufacturing and assembly.
Solution Approach 2:
The core members are connected to each other and to the resin compact simultaneously through integrated connection structures. The resin compact serves as both the structural support and the connecting medium, merging the functions of support and connection into a single unified structure.
2Ease of operation
If core members are temporarily assembled for molding, then assembly is simple, but the assembly is time-consuming and labor-intensive
Solution Approach 1:
Connection structures such as protrusions and recesses are pre-formed on the core members during manufacturing. This preliminary preparation eliminates the need for complex assembly operations and enables rapid connection when the core members are positioned in the mold.
Solution Approach 2:
The resin compact automatically performs the connection function between core members through its own structural features. The resin material itself provides the connecting mechanism, eliminating the need for separate connection components or complex assembly procedures.
3Reliability
If wire connections are made for each phase after coil winding, then electrical connections are established, but the process requires much time and labor
Solution Approach 1:
The electrical connection structures are merged with the mechanical connection structures in the core members. The same protrusions and recesses that provide mechanical support also serve as terminals for electrical connections, combining mechanical and electrical functions into a single integrated feature.
Solution Approach 2:
The connection structures on the core members serve multiple functions simultaneously: mechanical support, structural connection, and electrical terminal. This multi-functionality eliminates the need for separate wire connection operations while maintaining reliable electrical connections.
Data Source
AI summary
In an axial air-gap electronic motor in which a stator is formed by a plurality of core members, the manpower for assembling the core member is reduced, and the motor is assembled in a shorter period of time. A hook portion 320, which is a first connecting means, is projectingly provided at one end in the circumferential direction of a flange portion 310 of each of the core members 21a to 21i, and a columnar locking shaft 330 to which the hook portion 320 is locked is provided at the other end in the circumferential direction of the flange portion 310, by which the core members 21a to 21i are connected to each other.