DC Motor Stator Insulation Segmentation for Pump Reliability
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Solution Overview
Problem
Existing electrically commutated DC motors for liquid pumps are prone to damage and failure under extreme loads due to unstable connections and lack of securing measures, leading to reduced reliability and lifespan.
Innovation Solution
The DC motor design features a disk-shaped pump rotor with axially aligned stator poles, one-piece insulation elements with receptacles for secure winding and mounting of stator windings, and a radially and axially fastened circuit board, enhancing stability and robustness through shape-mated connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If connections are held only in a plug cover without special securing measures, then the structure is simple, but the reliability deteriorates under extreme loads and after longer running time
Solution Approach 1:
The connection structure is segmented into multiple functional components: plug cover, receptacles in insulation elements, circuit board with mounting features, and securing measures. This segmentation allows each component to perform its specific function while collectively providing stable and reliable connections that resist damage under extreme loads and prolonged operation.
2Adaptability or versatility
If multiple separate parts are used for insulation elements, then the adaptability is improved, but the assembly reliability deteriorates
Solution Approach 1:
The insulation elements are merged into one-piece structures that integrate multiple functions: electrical insulation, mechanical support for windings, and mounting receptacles for the circuit board. This merging reduces the number of separate parts, simplifies assembly, and improves assembly reliability while maintaining the adaptability needed for different motor configurations.
3Device complexity
If the circuit board is directly connected to winding connections without secure fastening, then the device complexity is reduced, but the stability deteriorates
Solution Approach 1:
The insulation elements are designed with receptacles that preliminarily position and secure the circuit board before final assembly. The circuit board includes mounting features that engage with these receptacles, ensuring proper alignment and stable connection before the motor is put into operation. This preliminary action prevents misalignment and instability during operation.
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 configuration simplifies assembly, improves stability, and extends the motor's lifespan by reducing the number of parts and ensuring secure alignment and fastening of components, resulting in a more reliable and robust DC motor for liquid pumps.
Implementation Method 1
an essentially disk-shaped pump rotor mounted to rotate in the pump housing, consisting of an impeller with several pump vanes and a permanent magnet, a partition separating a pump space from a dry space, the partition being arranged in an axial gap between the pump rotor and several axially aligned stator poles of the DC motor, each provided with an insulation element and a stator winding
Data Source
AI summary
An electrically commutated DC motor (1) for a liquid pump (2) with a pump housing (3) with a suction connector (4) and a pressure connector (5) for connection to a hydraulic circuit, an essentially disk-like pump rotor (6) mounted to rotate in the pump housing, consisting of an impeller (7) with several pump vanes and a permanent magnet (8), a partition (11) separating a pump space (9) from a dry space (10), the partition being arranged in an axial gap (12) between the pump rotor (6) and several axially aligned stator poles (14), each provided with an insulation element (15) and stator windings (16). The task of the present invention is to configure a DC motor, so that it can be installed simply and reliably, is designed particularly robust and therefore has very high lifetime.