External Rotor Motor Plastic-Packaged Stator Structural Integrity
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Solution Overview
Problem
Conventional external rotor motors with plastic-packaged stators have low structural integrity and are prone to failure during long-term use due to manufacturing difficulties.
Innovation Solution
An external rotor motor design featuring a plastic-packaged stator with a sleeve base, stator core, terminal insulator, coil windings, and a reinforced plastic body, including arms with reinforcing ribs and arc flanges, which increases structural strength and reliability through improved binding forces and assembly stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic-packaged stator is used in conventional external rotor motors, then the manufacturing process is simplified, but the structural integrity and reliability deteriorate
Solution Approach 1:
The patent merges the stator core, terminal insulator, and coil windings into a single integrated plastic-packaged stator assembly. This combining of multiple components into one unified structure simplifies the manufacturing process while maintaining structural integrity through the integrated design that prevents relative movement between components.
Solution Approach 2:
The patent employs composite construction by integrating metal stator core components with plastic packaging material and insulator materials. This composite approach allows the plastic package to provide both structural support and electrical insulation, simultaneously achieving ease of manufacture and reliable structural integrity through the synergistic properties of different materials.
2Device complexity
If a plastic-packaged stator is used in conventional external rotor motors, then the assembly process is simplified, but the structural strength deteriorates
Solution Approach 1:
The patent combines the stator core, terminal insulator, and coil windings into a pre-assembled plastic-packaged unit. This merging reduces assembly complexity by treating the stator as a single module that can be installed as one piece, while the integrated construction ensures structural strength by eliminating gaps and weak interfaces between separate components.
Solution Approach 2:
The patent applies preliminary action by pre-assembling and pre-positioning the stator core, terminal insulator, and coil windings within the plastic package before final motor assembly. This preliminary integration ensures proper alignment and structural strength are achieved during manufacturing, while simplifying the final assembly process to merely installing the complete stator module.
Data Source
AI summary
An external rotor motor, including: a rotary shaft; a plastic-packaged stator including a sleeve base, a stator core, a terminal insulator, coil windings, and a plastic-packaged body; and an external rotor sleeving on the plastic-packaged stator. The terminal insulator is disposed on the end face of the stator core. The coil windings are coiled on the terminal insulator. The sleeve base is disposed in an axle hole in the center of the stator core. The rotary shaft is disposed in the sleeve base. Two ends of the rotary shaft are supported by the bearing. One end of the rotary shaft protrudes out from the sleeve base and is connected to the external rotor. The top of the sleeve base extends outwards to form a plurality of arms, and the plurality of arms each includes an outer end which is provided with a bolt.