Elevator Motor Stator Casting for Compact Power
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Solution Overview
Problem
Elevator drives face challenges in minimizing space usage due to the large size requirements of conventional motors, particularly in gearless systems where high mechanical strength and effective heat dissipation are crucial for handling heavy loads and forces.
Innovation Solution
The stator side of the elevator drive is enhanced by casting a laminated core with windings and supporting components using a suitable casting compound, such as epoxy resin, to create a robust and compact stator-side unit that absorbs and distributes forces effectively, allowing for a smaller motor design and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional motors are used in elevator drives, then the drive can provide sufficient power, but the drive occupies a large amount of space
Solution Approach 1:
The patent combines the stator, housing, and supporting components into a single integrated casting unit. The stator is cast directly into the housing structure, eliminating the need for separate assembly of these components. This merging of functions allows the drive to maintain full power capability while occupying significantly less space, as the integrated design eliminates gaps and redundant structural elements between separate components.
Solution Approach 2:
The patent employs a composite construction where the casting compound (typically aluminum or aluminum alloy) integrates multiple functional elements. The casting material serves simultaneously as structural housing, stator support, and thermal management medium. This composite approach enables compact design while maintaining the mechanical strength and power transmission capabilities required for elevator drives.
2Volume of moving object
If the motor size is reduced to save space, then the space requirement decreases, but the mechanical strength and load-bearing capacity are compromised
Solution Approach 1:
By integrating the housing and stator into a single casting unit, the patent creates a monolithic structure that distributes mechanical loads throughout the entire casting rather than concentrating stresses at connection points between separate components. This unified structure maintains high mechanical strength despite reduced overall size, as the casting can be designed with optimized thickness and reinforcement in critical load-bearing areas.
Solution Approach 2:
The casting design incorporates local reinforcement and variable wall thicknesses in specific areas to maintain mechanical strength where needed. The housing casting can have thicker sections in load-bearing areas and thinner sections in non-critical areas, allowing the overall size to be reduced while preserving necessary strength characteristics through localized material distribution.
3Ease of manufacture
If conventional separate components are used, then assembly is straightforward, but the assembly process requires multiple steps and more time
Solution Approach 1:
The integration of stator, housing, and supporting components into a single casting unit eliminates the need for assembly operations between these components. What would traditionally require multiple assembly steps, fasteners, and alignment procedures is now achieved through a single casting process followed by minor post-processing. This dramatically reduces assembly time and eliminates potential assembly errors while maintaining ease of manufacture through the simplicity of the casting process.
4Power
If conventional motors are used, then the drive can handle loads, but heat dissipation is insufficient leading to energy loss
Solution Approach 1:
The casting compound serves multiple functions simultaneously: it provides structural support as housing, mounts the stator, and acts as a thermal management system. The large surface area of the aluminum casting naturally dissipates heat generated by the motor through conduction and convection, eliminating the need for separate cooling systems and reducing energy loss while maintaining full load handling capacity.
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 approach results in a more compact, efficient, and durable elevator drive with improved heat dissipation, enabling the use of gearless designs in limited spaces and extending service life by reducing material stresses, while also simplifying assembly and potentially eliminating the need for a drive housing.
Implementation Method 1
the laminated core with the windings of the stator and at least one supporting component of the stator are at least partially cast with a casting compound, preferably epoxy resin
Implementation Method 2
By using a suitable casting compound, preferably epoxy resin, any heat loss from the elevator can be dissipated in a particularly effective manner
Data Source
AI summary
The drive has a rotor (24), and a stator (22) comprising a lamination stack (22a) with windings (22b), where the stack is encapsulated with the windings. The windings are designed as two-layer windings. Carrier components to a stator-side unit are partially encapsulated with a casting compound (23), where the carrier components are a bearing bracket and a housing ring (21). The windings of stack and/or the rotor are formed as a single winding. Individual phases with changing upper and lower conditions can be introduced at the windings. Independent claims are also included for the following: (1) a method for manufacturing a stator-side unit of lift drive (2) a stator-side unit of an electromotor part of lift drive.