External Rotor Injection Molding for DC Motor Vibration Reduction
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Solution Overview
Problem
Conventional external rotors for direct current drive motors are heavy, expensive, difficult to produce, and prone to excessive vibration due to poor integrity and complex production processes.
Innovation Solution
An external rotor design featuring a side wall and end cover integrally formed by injection molding, with a base, center hole, and magnetic yoke shell, along with a rotating spline and supporting ribs, which reduces production complexity and cost while enhancing structural integrity and reducing vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional external rotors are constructed with separate components (side wall, end cover, magnetic conductive housing, magnetic tile), then assembly flexibility is improved, but manufacturing complexity and production cost increase
Solution Approach 1:
The side wall and end cover are merged into a single integrally formed component through injection molding, eliminating the need for separate assembly of these parts. This reduces the number of components from four separate pieces to one integrated structure, thereby simplifying the production process and reducing manufacturing complexity while maintaining the functional integrity of the rotor structure
2Stability of the object's composition
If conventional external rotors use multiple separate components, then ease of assembly is improved, but structural integrity deteriorates
Solution Approach 1:
By integrating the side wall and end cover into a single molded component, the invention eliminates interfaces and joints between these parts, thereby improving structural integrity and reducing vibration. The integral structure ensures uniform material properties throughout the component, enhancing overall stability and reliability of the rotor assembly
3Ease of manufacture
If conventional external rotors are constructed with traditional methods, then manufacturing flexibility is improved, but production cost increases
Solution Approach 1:
The integral injection molding of the side wall and end cover reduces the number of manufacturing steps by eliminating separate production and assembly operations. This streamlining of the production process reduces labor costs, material waste, and production time, thereby lowering overall manufacturing costs while improving production efficiency and scalability
Data Source
AI summary
An external rotor for a direct current drive motor with a side wall, an end cover, a cavity, an opening, a base, a magnetic tile, a center hole, and a magnetic yoke shell. A method for producing an external rotor for a direct current drive motor by integrally forming by injection molding a magnetic yoke shell and multiple magnetic tiles; forming a side wall on said magnetic yoke shell and an end cover at the bottom of said side wall; forming a base at the center of said end cover; and integrally forming by injection molding said base and a rotating spline.