Flat Multipole Motor with Stacked Sheet Metal Cores
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing drive units for revolving doors with electronically commutated multipole motors are complex and bulky, requiring intricate constructions and sealing, which complicates their installation and maintenance.
Innovation Solution
A drive unit with a flat, disk-shaped or cup-shaped electronically commutated multipole motor constructed from simple sheet metal elements, where the stator and rotor parts are formed by stacking sheet metal elements parallel to each other, allowing for a high torque-to-diameter ratio and eliminating the need for mechanical transmissions, thus simplifying installation and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multipole motors are constructed with housings, castings, and machined components to improve magnetic field circuit and sealing, then magnetic field performance is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The motor is divided into modular components: a stator assembly with stacked sheet metal stator cores, a rotor assembly with stacked sheet metal rotor cores, and separate end caps. This segmentation allows each module to be manufactured independently using simple stamping processes rather than complex casting or machining, reducing overall device complexity while maintaining magnetic field performance through proper stacking and alignment of the modular cores
Solution Approach 2:
The invention changes the manufacturing parameters from traditional casting/machining to sheet metal stamping and stacking. By using stamped sheet metal cores with appropriate lamination structures, the magnetic field circuit performance is maintained through controlled stacking sequences and magnetic path continuity, while eliminating the need for complex monolithic housings and castings
2Reliability
If multipole motors are constructed with traditional housings and output shafts to achieve best sealing, then sealing performance is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The invention merges the sealing function directly into the rotor assembly by providing a sealed rotor housing that encloses the rotor cores, magnets, and internal components. This integrated sealed unit eliminates the need for separate housing assemblies and output shaft seals, simplifying both manufacturing and installation while maintaining reliable sealing performance through the unified sealed structure
Solution Approach 2:
The invention replaces traditional mechanical sealing systems (output shafts requiring labyrinth seals or lip seals) with a magnetically coupled sealed structure. The rotor assembly is completely enclosed and sealed, with magnetic torque transmission occurring through the sealed barrier, eliminating mechanical wear points and simplifying installation by removing complex sealing requirements
3Force
If multipole motors use gearboxes to transmit rotational movement, then torque transmission is achieved, but device complexity and maintenance requirements increase
Solution Approach 1:
The invention replaces mechanical gear transmission systems with direct magnetic torque transmission. The rotor assembly is gearlessly connected to the turnstile, with rotational movement transmitted directly through magnetic coupling between the stator and rotor. This eliminates all gearbox components (gears, shafts, bearings, housings) while maintaining effective torque transmission, thereby reducing device complexity and maintenance requirements
4Force
If traditional motor constructions are used to achieve high torque, then torque output is sufficient, but motor size and build height increase
Solution Approach 1:
The invention transitions from a conventional longitudinal cylindrical motor design to a flat, disk-shaped construction. The stator and rotor cores are stacked axially in thin layers, with magnetic poles arranged in the radial direction. This dimensional reconfiguration allows high torque output to be achieved through increased radial and axial surface area for magnetic interaction, while minimizing the build height in the axial direction to under 80 mm
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
The solution enables a compact, high-torque drive unit suitable for revolving doors, reducing material usage and complexity, while maintaining a low maintenance requirement due to the use of sheet metal elements and eliminating the need for gearboxes.
Implementation Method 1
When the coil elements are supplied with current under electronic commutation, a magnetic field surrounding a drive axis is achieved by successively energizing the coil elements, resulting in a rotational movement of the rotor part at the stator part
Implementation Method 2
The coil elements have ferrite cores on which wound components are arranged. The magnet elements can also be received by ferritic elements which likewise optimize the magnetic field circuit
Data Source
AI summary
A drive unit for a door includes an electronically commutated multipole motor having: a stator part configured to be arrangable at a stationary structural component part; and a rotor part configured to be gearlessly connectable to a rotationally drivable element. The stator part and the rotor part include sheet metal elements stacked in a package-like manner. The sheet metal elements of the stator part and the sheet metal elements of the rotor part extend parallel to one another.