Brushless Motor Stator Reuse With Rotor Pole Variation
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Solution Overview
Problem
Producing different brushless motors for various electric work machines to meet specific output characteristics increases production costs.
Innovation Solution
The use of a dual-brushless motor configuration, where a first brushless motor with a specific stator and rotor combination is combined with a second brushless motor having a different number of poles and the same stator core shape, along with a controller to manage the magnetic field, reduces production costs by allowing a single stator core design to be used for multiple motor configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different brushless motors are produced for each type of electric work machine to meet specific output characteristics, then the output characteristics can be optimized for each machine type, but the production cost increases
Solution Approach 1:
The patent applies universality by designing a stator core that can serve multiple functions across different motor configurations. The same stator core structure is used in both the first and second brushless motors, allowing a single component design to support multiple output characteristics when combined with different rotors having different pole counts.
Solution Approach 2:
The patent segments the motor system into independent modular components: a universal stator core design and interchangeable rotors with different pole configurations. This segmentation allows the stator core to be produced once and reused across multiple motor types, while only the rotors need to be varied to achieve different output characteristics.
2Ease of manufacture
If a single stator core design is used for multiple motor configurations, then production cost is reduced, but the ability to achieve different output characteristics may be limited
Solution Approach 1:
The patent applies local quality by varying only the necessary local characteristic (number of poles in the rotor) while keeping the overall stator core structure uniform. This allows differentiation of motor output characteristics through localized changes in the rotor pole configuration rather than redesigning the entire motor structure.
Solution Approach 2:
The patent achieves different output characteristics by changing a key parameter (number of poles) in the rotor while maintaining the same stator core. By varying this single parameter across different rotor designs, multiple output characteristics can be obtained from a unified stator core platform.
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 approach reduces production costs by allowing a single stator core design to be used for multiple motor configurations, while maintaining the ability to achieve different output characteristics through the dual-motor configuration.
Implementation Method 1
a controller configured to magnetize the plurality of first teeth to cause the first rotor to rotate about the rotation axis
Implementation Method 2
a rotor including a rotor core and permanent magnets supported by the rotor core
Data Source
AI summary
An electric work machine includes a first brushless motor including a first stator and a first rotor combined with the first stator, and a controller. The first stator includes a first stator core and multiple first coils wound around multiple teeth on the stator core. The controller magnetizes the teeth to cause the first rotor to rotate about a rotation axis. In a plane orthogonal to the rotation axis, the first stator core has the same shape as a second stator core in a second stator used in a second brushless motor in another electric work machine. The first rotor can be combined with the second stator. The first rotor has a different number of poles from a second rotor used in the second brushless motor.