DC Motor Downsizing via Radial Choke Coil Orientation
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Solution Overview
Problem
Existing motor designs that incorporate choke coils to reduce electrical noise often result in larger motor sizes, and shortening these coils to downsize them can lead to a loss of noise reduction effectiveness.
Innovation Solution
A DC motor with a tubular housing featuring a polygonal shape and chamfered joining sections, allowing for non-parallel arrangement of electrical components, including choke coils and carbon brushes, which increases layout flexibility and reduces motor size while maintaining noise suppression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If choke coils are arranged in parallel with the rotational axis to reduce electrical noise, then noise reduction effect is improved, but motor size increases in axial and radial directions
Solution Approach 1:
The patent changes the arrangement dimension of choke coils from axial parallel orientation to radial orientation along the rotational axis. The coils are positioned to extend radially outward from the armature core, utilizing the radial space between the armature and housing rather than occupying axial length. This dimensional reconfiguration reduces motor size while maintaining noise reduction functionality.
Solution Approach 2:
The patent employs curved or bent choke coil structures that follow the radial geometry of the motor. Instead of straight axial coils, the coils are shaped to curve radially outward, optimizing space utilization and reducing interference with other motor components while maintaining the necessary inductance for noise suppression.
2Volume of stationary object
If choke coil length is shortened to downsize the motor, then motor size is reduced, but noise reduction effectiveness is lost
Solution Approach 1:
The patent changes the geometric parameters of the choke coils, specifically transitioning from long axial orientation to compact radial orientation. By adjusting the coil dimensions and arrangement angle to extend radially rather than axially, the design achieves shorter overall length while preserving the electrical characteristics necessary for effective noise reduction through maintained inductance values.
3Ease of manufacture
If electrical components are arranged parallel to side walls of polygonal housing, then layout is simplified, but component placement flexibility is limited
Solution Approach 1:
The patent employs asymmetric angular arrangements of electrical components relative to the polygonal housing sides. Instead of uniform parallel alignment, components are positioned at varied angles and orientations that optimize space utilization and accommodate different component sizes and shapes, thereby increasing placement flexibility while maintaining manufacturing feasibility.
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 is downsized without compromising reliability, with enhanced noise reduction and extended brush life due to optimized component placement and arrangement.
Implementation Method 1
a magnet disposed along inner peripheral surfaces of the housing, the magnet having magnetic poles in the joining sections
Implementation Method 2
a brush in sliding contact with an outer peripheral surface of the commutator
Implementation Method 3
a brush in sliding contact with an outer peripheral surface of the commutator
Data Source
AI summary
A motor includes a tubular housing having flat side walls along each side of rectangular joined with each other by joining sections, a magnet, having magnet poles in the jointing section, disposed along the inner peripheral surfaces of the housing, a shaft inserted along the axis of the housing, an armature fixed to the shaft in such a position as to be opposite to the magnet, a commutator mounted on the shaft, a carbon brush in sliding contact with the outer peripheral surface of the commutator, and electrical components provided within the housing. The electrical components in the longer direction are arranged such that they are not parallel with all the sides of the housing.