Flexible Groove Cover Assembly for Drive Motor Stator Slots
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Solution Overview
Problem
Existing drive motors with groove covers require significant flexural rigidity for insertion, making assembly complex and requiring high loading forces, which can restrict rotor movement and increase joining forces.
Innovation Solution
The groove cover is designed with a modified transverse spacing and flexible sections to allow radial insertion and locking, reducing the need for high flexural rigidity, using a flexible configuration and telescopic sections to facilitate easier assembly and reduce insertion forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the groove cover is designed with high flexural rigidity for insertion, then the groove cover can be pushed into the groove from the end face, but the frictional resistance increases and high loading forces are required which can restrict rotor movement
Solution Approach 1:
The groove cover is designed with a flexible wall section that can be deformed radially inward to reduce transverse spacing, enabling insertion without requiring high flexural rigidity. This flexible section allows the groove cover to adapt to the groove dimensions while being inserted from the radial direction, eliminating the need for high loading forces.
Solution Approach 2:
The transverse spacing between longitudinal sides of the groove cover is made variable through the flexible wall section. This parameter can be dynamically adjusted: reduced during insertion to pass through the groove opening, then restored to provide proper coverage and engagement. This parameter change resolves the contradiction between needing rigidity for structural integrity and flexibility for easy insertion.
2Ease of manufacture
If the groove cover is inserted radially with modified transverse spacing, then assembly is simplified and insertion forces are reduced, but the groove cover requires flexible sections instead of rigid structure
Solution Approach 1:
The wall section of the groove cover is specifically designed as a flexible element that enables radial insertion with reduced transverse spacing. This flexible section is positioned to allow deformation during insertion while maintaining structural integrity during operation. The flexibility is localized to the insertion region, while other portions of the groove cover maintain adequate rigidity for their functions.
Solution Approach 2:
The groove cover is segmented into different functional zones: a flexible wall section for insertion purposes, and rigid sections for structural support and engagement. This segmentation allows each part to have optimized properties for its specific function, resolving the contradiction between overall flexibility needed for assembly and local rigidity needed for structural performance.
3Reliability
If the transverse spacing of longitudinal sides is reduced for insertion, then the groove cover can engage behind the engage-behind contours, but the groove cover requires deformation capability
Solution Approach 1:
The flexible wall section is specifically designed to enable the groove cover to deform radially inward during insertion, allowing the longitudinal sides to pass behind the engage-behind contours. After insertion, the flexible section returns to its original shape, providing reliable engagement. This localized flexibility enables the locking mechanism without compromising the overall structural integrity.
Solution Approach 2:
The groove cover transitions from a static rigid structure to a dynamic structure with controlled flexibility. The flexible wall section allows temporary deformation during the insertion process to achieve engagement behind the contours, then stabilizes in the engaged position. This dynamic behavior enables reliable locking while minimizing the need for overall high flexural rigidity.
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 design simplifies the assembly process, reduces the required joining forces, and maintains the rotor's freedom of movement while providing a secure locking mechanism.
Implementation Method 1
the wall section of the groove cover is designed as a flexurally flexible section or has such a flexurally flexible section, wherein the flexurally flexible section can be deformed in terms of reducing the transverse spacing of the longitudinal sides of the groove cover
Implementation Method 2
The groove covers must be designed to be correspondingly flexurally rigid. The further the groove cover is inserted into the groove, the greater the frictional resistance.
Data Source
AI summary
A drive motor for a suction device or a machine tool in the form of a handheld power tool or a semi-stationary machine tool, wherein the drive motor includes a stator having an excitation coil assembly and a rotor having a motor shaft, which is rotatably mounted around a rotational axis on the stator or with respect to the stator by means of a bearing assembly, wherein the rotor is received in a rotor receptacle of the stator, the inner circumference of said receptacle having grooves which extend along longitudinal axes that run parallel to the rotational axis and have insertion openings which are open towards the rotational axis and are provided for inserting excitation coils of the excitation coil assembly and are closed by groove covers, wherein the groove covers are in engagement with the engage-behind contours of the grooves at their opposite longitudinal sides, each of which extends along the longitudinal axis of the respective groove, said longitudinal axis being transverse to a transverse spacing between the longitudinal sides, and the groove covers have a wall section for covering the groove between the longitudinal sides.