Brushless Motor Strut Alignment for Noise Reduction
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Solution Overview
Problem
Existing brushless motors face challenges in reducing size, weight, manufacturing cost, efficiency, reliability, and noise, particularly due to turbulence and noise generated by airflow around structural components.
Innovation Solution
The motor design aligns the stator assembly and struts along a line parallel to the rotor's rotation axis, positioning the strut within the slipstream of the stator assembly to minimize airflow direction changes, with tapered and aerodynamically shaped struts to reduce turbulence and noise, and a frame structure that integrates an impeller shroud for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If struts are added to support the rotor and stator assemblies, then the motor's strength and stability are improved, but turbulence and noise increase due to airflow changes around the struts
Solution Approach 1:
The strut is positioned within the slipstream of the stator assembly, converting the potentially harmful airflow disruption into a beneficial arrangement where the strut utilizes the existing airflow path. This alignment ensures that air flows over the stator assembly and then the strut in sequence, minimizing turbulence and noise while maintaining the structural support function
Solution Approach 2:
The strut is designed with a tapered cross-section that decreases in area along the airflow direction. This dimensional change in the cross-sectional area creates an aerodynamic profile that reduces airflow separation and turbulence, allowing the strut to provide structural support while minimizing its harmful impact on airflow
2Volume of moving object
If the motor size is reduced, then compactness is improved, but structural stability and strength may be compromised
Solution Approach 1:
The strut is nested within the existing airflow path created by the stator assembly, utilizing the available space efficiently. By positioning the strut within the slipstream area rather than adding external support structures, the design maintains structural stability without increasing the overall motor volume
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 reduces turbulence and noise within the motor, improves airflow efficiency, and enhances the motor's strength and stability by minimizing airflow direction changes and incorporating an integrated impeller shroud for simplified construction.
Implementation Method 1
the strut is tapered in a direction away from the stator assembly. Thus the strut is aerodynamically shaped and thus contributes further to a reduction in turbulence and noise within the motor
Data Source
AI summary
A brushless motor comprising a rotor assembly comprising a shaft, an impeller, a bearing assembly and a rotor core; a stator assembly; a frame comprising an outer portion and a support portion radially inward of the outer portion, the support portion supporting at least one of the rotor assembly and the stator assembly; and at least one strut extending between the outer portion and the support portion, wherein the strut and the stator assembly are aligned such that at least part of the strut and at least part of the stator assembly are disposed along a line substantially parallel to a rotation axis of the rotor assembly.