Compact Gear Motor with Segmented Stator Teeth
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Solution Overview
Problem
Existing geared motors face challenges in achieving optimal size and mass reduction while maintaining performance and integrating with reducers, particularly in industrial and automotive applications where cost, lifespan, size, and mass are critical criteria.
Innovation Solution
A polyphase electric motor design with a stator featuring wide and narrow teeth, optimized coil placement, and a reduction gear system that minimizes residual torque and copper volume, allowing for compact integration with a reducer while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the motor is integrated with a reducer to minimize size, then the external dimensions are reduced, but the mass and complexity of integration increase
Solution Approach 1:
The motor and reducer are merged into a single integrated unit where the motor stator serves as the reducer housing. The motor shaft is directly coupled to the pinion gear, eliminating the need for separate mounting flanges and coupling mechanisms. This integration reduces the number of external components and simplifies the overall structure while maintaining compact dimensions.
Solution Approach 2:
The stator structure serves multiple functions: it provides the magnetic circuit for motor operation, acts as the housing for the reduction gear mechanism, and serves as the mounting structure for the entire assembly. This multi-functionality reduces the number of separate components needed and simplifies integration with the reducer.
2Ease of manufacture
If the number of coils is reduced to simplify connections, then the manufacturing complexity decreases, but the torque performance may be compromised
Solution Approach 1:
The stator teeth are designed with varying widths: wider teeth at positions where coils are wound to provide sufficient magnetic flux and torque, and narrower teeth where no coils are placed. This local variation in tooth width optimizes the magnetic circuit efficiency at coil locations while maintaining structural integrity elsewhere, ensuring adequate torque performance with fewer coils.
3Loss of substance
If wide teeth and narrow teeth are used to optimize copper volume, then the copper usage is minimized, but the manufacturing precision requirements increase
Solution Approach 1:
The stator circumference is segmented into alternating wide and narrow teeth, with each tooth type serving specific functions. Wide teeth accommodate coils and provide primary torque generation, while narrow teeth provide structural support and magnetic flux pathways. This segmentation allows optimization of copper placement while maintaining manufacturability through standardized tooth patterns.
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, economical, and robust geared motor with reduced external dimensions and mass, optimized copper volume, and low residual torque, suitable for large series production.
Implementation Method 1
a rotor (14) having N pairs of poles (A1 to A10) magnetized radially in alternate directions
Implementation Method 2
The windings (15 to 17) are placed around the wide teeth (2 to 7) which makes it possible to obtain the maximum torque per ampere-turn of the motor
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a gear motor including a multiple-phase electric motor formed by a stator portion excited by electric coils and by a rotor having N pairs of poles radially magnetised in alternating directions, the stator portion including two angular sectors alpha-1 and alpha-2 with respective radii R1 and R2, comprising wide teeth and narrow teeth radially extending from an annular crown, characterised in that the wide teeth have a width higher than or equal to twice the width of the narrow teeth, in that the notch width is higher than the width of a narrow tooth, in that the angular sector alpha-1 is lower than 220° and includes all the coils, and in that the ratio R1/R2 ranges from 1.2 to 2.