Brushless Motor Coil Support Wall for Higher Rigidity
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Solution Overview
Problem
The existing brushless motor designs face challenges in increasing the rigidity of the coil support wall without complicating the structure or manufacturing process, often requiring reinforcing members that add complexity.
Innovation Solution
The design incorporates a coil support wall made of resin with a first and second wall part connected at an angle, where the second wall part's thickness is equal to or greater than the first wall part's, providing increased rigidity without the need for reinforcing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a resin material or metal material (reinforcing member) having a higher rigidity than the insulator is embedded inside the insulator to increase the strength of the coil support wall, then the rigidity of the coil support wall is improved, but the structure of the insulator becomes complicated and the manufacturing process becomes complicated
Solution Approach 1:
The coil support wall is designed with non-uniform thickness, where the second wall part has a greater thickness than the first wall part. This local variation in thickness concentrates the rigidity enhancement where most needed (at the second wall part) without requiring reinforcing members throughout the entire structure, thus improving rigidity while maintaining structural simplicity
Solution Approach 2:
The invention changes the geometric parameters of the coil support wall by varying its thickness across different sections. By making the second wall part thicker than the first wall part, the structure achieves higher rigidity through parameter optimization rather than through material reinforcement, avoiding the need for embedded reinforcing members
2Strength
If a resin material or metal material (reinforcing member) having a higher rigidity than the insulator is embedded inside the insulator to increase the strength of the coil support wall, then the rigidity of the coil support wall is improved, but the manufacturing process becomes complicated
Solution Approach 1:
The coil support wall features localized thickness variation with the second wall part being thicker than the first wall part. This local quality approach allows the insulator to be manufactured as a single integrated piece with varying thickness, avoiding the complex multi-step process of embedding reinforcing members while achieving the desired rigidity enhancement
Solution Approach 2:
By changing the thickness parameter of the coil support wall at different locations, the invention achieves rigidity improvement through geometric optimization rather than material composition changes. This simplifies the manufacturing process to a single molding operation rather than multiple assembly steps required for embedding reinforcing members
3Strength
If the thickness dimension of the second wall part in a radial direction is made equal to or larger than the thickness dimension of the first wall part, then the rigidity of the coil support wall is increased, but the amount of resin material used increases
Solution Approach 1:
The coil support wall is designed with non-uniform thickness distribution, concentrating the increased material quantity only where structurally necessary (at the second wall part). This local quality approach minimizes the overall amount of resin material while achieving the required rigidity enhancement, rather than uniformly increasing thickness throughout
Data Source
AI summary
In a brushless motor including a stator core and a rotor which rotates with respect to the stator core, a coil support wall supports a coil wound around a core main body part from a radially inner side of the core main body part. A first wall part and a second wall part constituting the coil support wall are connected to each other at an angle at a portion of a tooth tip part protruding from a tooth main body part along a circumferential direction of the core main body part, and a thickness dimension of the second wall part is equal to or larger than a thickness dimension of the first wall part along a radial direction of the core main body part.