External Rotor Motor Cast Stator Space Reduction
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Solution Overview
Problem
Existing external rotor electrical machines have a significant installation space requirement due to the shaft and associated rotatable mounting passing through the stator, which limits their compactness.
Innovation Solution
Mechanical forces are introduced into the stator via a casting compound, allowing the mounting between the stator and rotor to be moved outside, with the use of bearing seat elements, such as metal materials like aluminum, and a configuration of the stator core and winding heads to minimize space, enabling a more compact construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shaft and associated rotatable mounting are passed through the stator to enable rotor mounting, then the rotor can be rotatably mounted on the stator, but the installation space requirement increases
Solution Approach 1:
The shaft and its associated rotatable mounting components are completely removed from the stator interior. Instead, the rotor is mounted externally on the stator using a simplified mounting structure that attaches to the stator's outer surface, eliminating the space-consuming shaft penetration through the stator core.
Solution Approach 2:
The mounting arrangement transitions from a radial/axial configuration (shaft passing through the stator) to an external circumferential configuration (mounting structure attached to the stator's outer surface). This dimensional repositioning eliminates the need for internal shaft space while maintaining rotational functionality.
2Volume of moving object
If the mounting between stator and rotor is moved outside, then the installation space requirement is reduced, but the mechanical force transmission path must be redesigned
Solution Approach 1:
The mounting structure combines multiple functions into a single integrated component: it provides external rotor mounting, serves as the mechanical force transmission path from rotor to stator, and acts as a structural support element. This merging eliminates the need for separate shaft and mounting components while simplifying the overall force transmission path.
Solution Approach 2:
The mounting structure acts as an intermediary element that transfers mechanical forces between the rotor and stator without requiring direct internal connection. It mediates the force transmission by attaching to the stator's outer surface and supporting the rotor externally, simplifying the force path while reducing space requirements.
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 reduces the installation space requirement and enhances the mechanical load-bearing capacity of the stator, achieving a more compact and efficient design for external rotor electrical machines.
Implementation Method 1
The casting compound typically serves to protect the coil winding against, in particular, mechanical impairments
Implementation Method 2
a first bearing seat element, which may be arranged between the casting compound and a first bearing for rotatably mounting the rotor
Implementation Method 3
forces that are transmitted via a mounting of a rotor and absorbed by a stator of an electrical machine may be at least partially introduced into a stator via a casting compound
Implementation Method 4
The electrical machine serves to convert electrical energy into mechanical work. Here, magnetic fields may be generated by means of the electrical energy, which magnetic fields in turn set the rotor in rotation relative to the stator
Data Source
AI summary
An electric machine may be an external rotor motor with a stator and a rotor surrounding the stator. The rotor may be mounted on bearings so as to be rotatable around an axis of rotation relative to the stator, where the mechanical forces transmitted by the bearings of the rotor may be absorbed at least in part by the stator. The stator may have a coil winding for generating a magnetic field, the coil winding being surrounded at least partially by a casting compound. At the output, the mechanical forces of the rotor or the device transmitted by the bearings and taken up by the stator may be introduced into the stator largely via the casting compound. The casting compound thus reduces induced vibrations.