External-Rotor Stator Assembly With Overmolded Carrier Integration
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Solution Overview
Problem
Existing stator assemblies for brushless electric motors in external rotor configurations are complex and require numerous individual parts, leading to increased production complexity and potential for tolerance issues.
Innovation Solution
A stator assembly design featuring a stator main body with a shaft feedthrough, radially oriented stator teeth, and a hollow-cylindrical stator carrier, integrated with a bi-component plastic structure, where the stator insulation and carrier are overmolded to form a materially integral connection, allowing for fewer parts and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stator assemblies use multiple separate components (stator body, insulation, carrier, fastening elements), then each component can be manufactured and assembled independently, but the overall device complexity increases and production time is extended
Solution Approach 1:
The patent merges the stator body, insulation, and carrier into a single integrated stator assembly where the insulation is formed as an integral part of the stator body, and the carrier is mounted directly to the stator body. This consolidation eliminates the need for separate fastening elements and reduces the number of assembly steps, directly resolving the contradiction between ease of manufacture and device complexity.
Solution Approach 2:
The stator body is designed to serve multiple functions simultaneously: it provides the structural framework, incorporates the insulation as an integral component, and serves as the mounting base for the carrier. This multi-functionality reduces the overall component count and simplifies the assembly structure, addressing the contradiction between manufacturing simplicity and device complexity.
2Ease of operation
If multiple separate components are used in the stator assembly, then assembly flexibility is maintained, but the number of assembly steps and potential tolerance issues increase
Solution Approach 1:
By combining the insulation and stator body into a single integrated component, the patent eliminates the need for separate assembly steps for these parts. The carrier is then mounted directly to the stator body in a single operation, significantly reducing assembly time and the accumulation of tolerance errors that would occur with multiple separate components.
3Ease of repair
If traditional fastening methods with separate elements are used, then adjustment and repair are easier, but the reliability and structural integrity are reduced
Solution Approach 1:
The integrated design where insulation is formed as part of the stator body and the carrier is directly mounted creates a more reliable and structurally sound assembly. While separate fastening elements would allow for easier disassembly, the direct mounting method provides superior structural integrity and eliminates potential failure points from additional connection interfaces.
Data Source
AI summary
A stator assembly for an electric motor having an external rotor configuration includes a stator main body having a shaft feedthrough and radially orientated stator teeth for a stator or rotary field winding with radially orientated connection wires. A stator insulation covers the stator main body at least in regions, and a hollow cylindrical stator carrier, which is connected to the stator main body and/or to the stator insulation, protrudes axially from the stator main body. An electric motor having the stator assembly, and a drive device for a motor vehicle having the electric motor and a drive housing, are also provided.