BLDC Motor Stator Core Geometry for Cleaner Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
BLDC motors used in cleaners face challenges in achieving high heat releasing performance and efficiency due to limitations in stator core design and magnet configuration, which affect motor performance and air movement resistance.
Innovation Solution
A BLDC motor design featuring a stator core with alternately formed straight and curved portions, teeth protruded towards the magnet, and a specific ratio of neck width to shoe end portion width, along with a rotor comprising multiple magnets, optimizes heat release and efficiency by maximizing coil winding area and reducing air resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the stator core uses a conventional design with limited coil winding area, then the manufacturing is simpler, but the motor efficiency and heat releasing performance are insufficient
Solution Approach 1:
The stator core is divided into multiple teeth (first tooth, second tooth, third tooth) with distinct structural features. Each tooth includes a neck portion and a shoe end portion with specific width ratios, allowing independent optimization of coil winding space and magnetic flux distribution. This segmentation enables enhanced efficiency without requiring a complete redesign of the entire stator core.
Solution Approach 2:
The patent applies different geometric characteristics to different parts of the stator core. The neck portion has a optimized width ratio (2.5≤A/B≤3.5) relative to the shoe end portion, creating localized regions with enhanced properties for coil winding and heat dissipation. This local optimization improves motor efficiency without significantly increasing overall complexity.
2Temperature
If the magnet configuration and stator core shape are conventional, then the manufacturing process is simpler, but the heat releasing performance is insufficient
Solution Approach 1:
The stator core incorporates curved portions in addition to straight portions, creating a hybrid geometry that enhances heat dissipation pathways. The curved sections improve air flow patterns around the coil windings, facilitating better thermal management. This curvature integration is achieved through standard manufacturing processes without requiring complex tooling.
Solution Approach 2:
The patent optimizes specific geometric parameters including the width ratio A/B of the neck to shoe end portion (2.5≤A/B≤3.5) and the pole pitch to internal arc length ratio (1.35≤C/D≤1.8). These parameter adjustments enhance heat releasing performance while remaining within standard manufacturing capabilities and tolerances.
3Productivity
If the stator core design does not optimize coil winding area, then the structure is simpler, but the motor efficiency cannot reach 90% or more
Solution Approach 1:
The patent establishes specific parameter ranges to achieve high efficiency: the width ratio A/B of the neck to shoe end portion is optimized to 2.5≤A/B≤3.5, and the pole pitch to internal arc length ratio C/D is optimized to 1.35≤C/D≤1.8. These parameter specifications provide clear manufacturing targets that balance precision requirements with achievable efficiency goals of 90% or more.
4Speed
If the air movement resistance is not reduced through optimized stator core shape, then the design is more straightforward, but the air movement performance deteriorates
Solution Approach 1:
The integration of curved portions in the stator core creates smoother air flow paths, reducing turbulence and resistance. The curved sections work in conjunction with the straight portions to guide air movement more efficiently through the motor, enhancing air movement speed without requiring a complete redesign of the air passage geometry.
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
The optimized design enhances heat releasing performance and motor efficiency, achieving efficiency of approximately 90% or more by optimizing the stator core shape and magnet configuration, thereby improving air movement and motor performance.
Implementation Method 1
a coil wound in the stator core and that generates a magnetic field by applied power
Data Source
AI summary
A Blushless Direct Current (BLDC) motor may include a motor housing; a stator including a stator core installed within the motor housing and a coil wound in the stator core and that generates a magnetic field by applied power; and a rotor disposed within the stator and in which a magnet that interacts with the magnetic field is installed and that rotates within the stator by an interaction with the magnetic field. The stator core may include a back yoke in which straight portions and curved portions are alternately formed; and teeth protruded from the back yoke toward the magnet. The tooth include a neck protruded from the back yoke, and a shoe protruded from the neck and separated from the magnet and that encloses at least a portion of the magnet. A ratio A/B of a width A of the neck to a width B of a shoe end portion is 2.5 to 3.5. By optimizing a ratio A/B of a width A of the neck to a width B of the shoe end portion constituting the stator core, efficiency of a BLDC motor may be maximized.