Brushless Gear Motor Stator Insulation for Precise Centering

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Solution Overview

Problem

Existing brushless gear motor assemblies face challenges in electrical connection, concentricity issues due to bearings being far from the magnetic core, and complex assembly of insulator parts on the stator core.

Innovation Solution

The assembly incorporates plastic parts with cut corners and chamfered protrusions on the stator ends for flexibility, direct bearing guidance, and overmolded spherical bearings for precise centering, along with simplified electrical connections using crimp terminals and conductive tracks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If insulator parts are assembled on each side of the stator core with high precision requirements, then proper alignment and centering is achieved, but assembly complexity and difficulty increase

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The insulator parts incorporate protrusions with cut corners that change the geometric parameters of the fitting interface. This modification allows the protrusions to be inserted into slots at slight angles and then forced into full engagement, transforming a precision alignment problem into a more tolerant assembly process while maintaining proper positioning

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The insulator parts are designed with multiple protrusions that fit into corresponding slots, dividing the single complex alignment operation into multiple simpler insertion points. The cut corner features on individual protrusions allow each to be assembled independently with reduced precision requirements

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If bearings are positioned far from the magnetic core, then easier assembly is achieved, but concentricity problems occur between rotor and stator axes

Engineering Contradiction:

Improveassembly easeVSAvoidconcentricity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The insulator parts serve as intermediary components between the bearings and the stator core. They provide a mounting structure that positions bearings close to the magnetic core while maintaining proper concentricity through their fitted design with the stator core slots, eliminating the need to position bearings far away

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If intermediate parts or soldering are used to connect terminals to control board, then electrical connection reliability is improved, but device complexity and assembly steps increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnection complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulator parts are designed to integrate multiple functions: electrical insulation, mechanical support for terminals, and direct mounting structure for crimp terminals. By combining these functions into single components rather than using separate intermediate parts, the design achieves reliable electrical connections while reducing overall device complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulator parts with integrated terminal mounting features enable the stator assembly to self-connect to the control board through crimp terminals without requiring external intermediate connectors or complex soldering operations, simplifying the assembly process while maintaining connection reliability

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12537414B2Brushless gear motor with plastic insulation parts on core ends with protruding parts having cut corners

Publication Date: 2026.01.27 INTEVA PRODUCTS LLC

AI summary

A stator assembly for use with a brushless geared motor assembly, including: two plastic parts located on each end of a core of the stator assembly, at least one of the plastic parts including several protruding parts configured to fit into complementary slots of the stator core, wherein the protruding parts are cut at corners in order to provide flexibility to the protruding parts.