Compact Electric Motor with Skewed Stator and Sealed Housing
Solution Overview
Problem
Utility vehicles face challenges in accommodating powerful electric motors due to size and weight constraints, as well as the need for protection in harsh environments, with existing motors being too large and heavy for practical use in these applications.
Innovation Solution
The design of a compact and efficient electric motor with a 12-slot stator and 10-pole rotor configuration, featuring a skewed stator lamination stack and convex magnets, along with a two-piece housing for improved sealing and thermal conduction, and a hub for securing implements, which includes a terminal box for low profile and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If standard off-the-shelf motors with sufficient torque are used, then power capacity is improved, but size and weight increase making them too large and heavy for practical utility vehicle application
Solution Approach 1:
The patent applies parameter changes by modifying the motor's physical dimensions and configuration parameters. The motor is designed with a compact form factor featuring a reduced stator outer diameter, optimized lamination stack height, and condensed magnetic circuit parameters. These parameter adjustments enable the motor to deliver sufficient torque and power capacity while reducing overall weight and size to practical levels for utility vehicle applications.
2Power
If standard off-the-shelf motors with sufficient torque are used, then power capacity is improved, but physical dimensions increase causing clearance problems for vehicle designer
Solution Approach 1:
The patent employs parameter changes to reduce the motor's physical dimensions. By optimizing the stator outer diameter, lamination stack height, and airgap dimensions, the motor achieves compact volume while maintaining sufficient power capacity. The skewed stator lamination design and optimized magnetic circuit further contribute to space efficiency, enabling the motor to fit within tight clearance constraints of utility vehicle applications.
3Volume of moving object
If motor is designed for compact size, then clearance issues are reduced, but protection in harsh environments becomes more challenging
Solution Approach 1:
The patent applies sealing mechanisms including lip seals and gaskets to protect the compact motor interior from harsh environmental conditions. The housing design incorporates sealed enclosures that prevent water and debris ingress while maintaining the motor's compact form factor. These protective elements ensure reliability without compromising the reduced size benefits.
4Reliability
If two-piece housing design is used, then sealing is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs a two-piece housing design segmented into upper and lower sections. This segmentation enables the incorporation of sealing mechanisms at the mating interface, improving protection against environmental contaminants. While the segmented design enhances sealing performance, the housing components are designed for ease of assembly and manufacturing using conventional processes.
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 motor provides improved efficiency, reduced size, and enhanced reliability for utility vehicle applications, enabling effective power transmission while minimizing clearance issues and weight, suitable for driving auxiliary implements like mowing blades.
Implementation Method 1
Stator laminations minimize airgap reluctance, facilitating a high level of flux coupling between the rotor and stator
Implementation Method 2
a skewed stator lamination stack
Implementation Method 3
PMS motors create stationary poles on the rotor using fixed high-energy magnets
Implementation Method 4
two-piece housing for improved sealing and thermal conduction
Implementation Method 5
a hub connected to a lower end of the shaft to rotate therewith in relation to the cone-shaped portion. The hub is configured to secure an operable implement to the electric motor
Data Source
AI summary
An electric motor includes an upper housing, a lower housing including a flange for mounting the upper housing thereon and a cone-shaped portion extending away from the flange and the upper housing. The electric motor further includes a stator assembly formed of a first core having a first height and fitted into the upper housing, a rotor assembly rigidly joined to a shaft to rotate therewith within the stator assembly and formed of a second core having a second height, and a hub connected to a lower end of the shaft to rotate therewith in relation to the cone-shaped portion. The hub is configured to secure an operable implement to the electric motor. The second height is greater than the first height.