Electric motor, food processor and method of manufacturing
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Solution Overview
Problem
Existing electric motors for food processors face challenges in achieving a simple, compact, stable, and cost-effective design with efficient operation, low noise emissions, effective heat dissipation, and high power density.
Innovation Solution
The electric motor features a stator with a coil carrier manufactured in one piece by injection molding onto the stator core, providing a compact design, improved stability, and direct contact for enhanced heat dissipation, along with radially arranged holders for connection and sensor devices, eliminating the need for internal installation space and facilitating easy access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-part coil carrier is used that is plugged onto the stator core, then assembly is simpler, but wall thickness increases and heat dissipation deteriorates
Solution Approach 1:
The coil carrier is merged with the stator core into a single integrated component manufactured by injection molding. This eliminates the need for separate assembly of two parts, reduces wall thickness, and improves heat dissipation by creating direct thermal contact between the coil carrier and stator core.
2Adaptability or versatility
If the coil carrier is manufactured separately and installed subsequently, then manufacturing flexibility is improved, but production time increases and cost-effectiveness deteriorates
Solution Approach 1:
The coil carrier and stator core are combined into a single molded part, allowing them to be manufactured together in one process. This eliminates subsequent installation steps, reduces production time, and improves cost-effectiveness while maintaining design flexibility through the molding process.
3Volume of moving object
If internal installation space is used for connection and sensor devices, then structural compactness is improved, but accessibility and installation ease deteriorate
Solution Approach 1:
The connection and sensor devices are arranged radially on the outer circumference of the stator core rather than internally. This dimensional repositioning maintains structural compactness while dramatically improving accessibility and ease of installation from the outside.
4Manufacturing precision
If air gaps are present between coil carrier and stator core, then manufacturing tolerance is improved, but heat dissipation and structural stability deteriorate
Solution Approach 1:
The coil carrier and stator core are merged into a single injection-molded part, eliminating air gaps between them. This ensures direct thermal contact for improved heat dissipation and rigid structural connection, while the molding process inherently accommodates manufacturing tolerances.
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 results in an electric motor with low noise emissions, high power density, and a large speed range, enabling efficient operation and precise control, suitable for applications like food processors, with improved manufacturing efficiency and reduced costs.
Implementation Method 1
the coil carrier is manufactured in one piece by injection molding onto or around the stator core
Implementation Method 2
it can be ensured that the coil support rests directly on the stator core, is positively connected to the stator core in all spatial directions and/or is connected to the stator core in a materially bonded and/or adhesive manner
Implementation Method 3
heat dissipation is also improved by the direct contact of the coil carrier and stator core, since insulating air gaps or the like can be avoided
Implementation Method 4
In brushless DC motors, the stator is equipped with stator coils and the rotor with permanent magnets
Implementation Method 5
In switched reluctance motors, the stator is also equipped with stator coils, but the rotor does not have any permanent magnets or coils, but consists exclusively of electrical steel or the like. The torque in the rotor is generated exclusively by the reluctance force.
Data Source
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AI summary
An electric motor, particularly for a food processor, is proposed, wherein the stator of the electric motor comprises a stator core, several coils, and a coil carrier. The coil carrier is manufactured in one piece by injection molding onto the stator core and has at least one support arranged radially outside the stator core, the support holding a connection device and/or a sensor device. A food processor with a corresponding electric motor is also proposed. Furthermore, a method for manufacturing an electric motor is proposed, in which a coil carrier of the stator is manufactured by injection molding onto a stator core, the coil carrier being manufactured with at least one support arranged radially outside the stator core and configured to hold a connection device and/or a sensor device.