Electric Power Steering Rotor with Nested Cover Support
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Solution Overview
Problem
Existing rotor designs for electric power steering motors face challenges in securely supporting the rotor core and magnets while minimizing axial size and preventing axial and rotational misalignment, which can lead to increased manufacturing complexity and size.
Innovation Solution
A rotor design featuring a rotor core that rotates about a central axis, with magnets positioned radially outside, a holder supporting the core and magnets, and a rotor cover with a cylindrical portion that surrounds and supports the assembly, including a first and second bent portion to securely attach the rotor cover, reducing the need for additional manufacturing processes and minimizing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rotor cover is used to support the rotor core and magnets, then the rotor structure is stabilized, but the axial size increases and manufacturing complexity increases
Solution Approach 1:
The support portion is nested within the rotor cover structure, where the rotor cover includes an inner wall that forms the support portion. This nested configuration allows the support function to be integrated into the rotor cover itself, eliminating the need for separate support components and reducing axial size while maintaining structural stability.
Solution Approach 2:
The support portion utilizes the radial dimension by forming a protruding structure from the inner wall of the rotor cover. This radial protrusion provides axial support functionality without increasing the axial length, effectively using another spatial dimension to resolve the contradiction between stability and compactness.
2Manufacturing precision
If additional support structures are added to prevent misalignment, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The support portion serves multiple functions simultaneously: it provides axial support for the rotor core and magnets, prevents axial displacement, and prevents rotational misalignment through its circumferential engagement. This multi-functional design eliminates the need for separate alignment features, reducing structural complexity while maintaining high alignment precision.
Solution Approach 2:
The support portion combines axial support and rotational alignment functions into a single integrated structure. By merging these functions into one component rather than using separate elements, the design reduces overall complexity while achieving precise alignment and support.
Data Source
AI summary
A rotor core that rotates about a central axis includes magnets located radially outside of the rotor core and disposed along a circumferential direction, a holder including a support portion that supports the rotor core and the magnets from a first side in an axial direction, and a rotor cover including a cylindrical portion that surrounds the rotor core, the magnets, and the holder from an outside in a radial direction and that opens toward the first side. The rotor cover includes a bottom portion that supports the rotor core from a second side of the rotor core in the axial direction. A radially outer edge portion of the support portion includes a first portion and a second portion adjacent to the first portion in the circumferential direction.