Hub Motor Stator Integration and Cable Sealing for Low-Noise Durability
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Solution Overview
Problem
Existing hub-type electric driving devices face challenges in structural rigidity, durability, and noise reduction due to weak coupling between the stator and motor shaft, biased center of gravity, and inadequate cooling and sealing of power lines.
Innovation Solution
The hub-type electric driving device incorporates an integrated core frame with radially extended teeth on the stator's outer circumference, a balanced support structure, and a cable guide bracket for easy cable introduction and sealing, along with a three-connection method for coil winding to minimize resistance and cogging noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the stator is coupled to the motor shaft using a conventional weak coupling structure, then the device complexity is reduced, but the structural rigidity and durability are compromised
Solution Approach 1:
The stator and motor shaft are merged into a single integrated component where the stator body directly encompasses the motor shaft. This integration eliminates the need for separate coupling structures, thereby achieving high structural rigidity and durability while avoiding increased device complexity.
2Speed
If an asymmetric double-rotor and single-stator type BLDC motor is used, then the initial maneuverability is improved, but the center of gravity becomes biased causing partial wear and noise
Solution Approach 1:
The patent employs an asymmetric double-rotor and single-stator configuration where the inner rotor and outer rotor have different geometries and magnetic pole arrangements. This controlled asymmetry optimizes the magnetic field distribution to improve initial maneuverability while the precise engineering of the asymmetric structure prevents center of gravity bias, thereby avoiding noise and wear issues.
3Ease of manufacture
If power lines are passed through the motor shaft without proper sealing, then the ease of manufacture is improved, but the reliability is reduced due to inadequate sealing
Solution Approach 1:
A cable guide bracket is introduced as an intermediary component between the power lines and the motor shaft. This bracket provides a dedicated sealed pathway for cable introduction, maintaining reliability through proper sealing while preserving ease of manufacture by guiding cables through a pre-designed route.
Solution Approach 2:
The sealing function is segmented from the motor shaft body and implemented through a separate cable guide bracket. This segmentation allows the bracket to be specifically optimized for sealing and cable guidance, ensuring reliability without complicating the overall manufacturing process.
4Device complexity
If the housing serves dual purposes as both motor casing and cooling structure, then the device complexity is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The housing is designed as a multi-functional component that simultaneously serves as the motor casing, structural support, and cooling structure. Integrated cooling channels are incorporated into the housing design, allowing it to perform multiple functions without requiring separate dedicated components, thereby reducing device complexity while managing manufacturing precision through unified design.
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 enhances structural rigidity and durability, reduces noise and resistance, improves assembly efficiency, and ensures effective cooling and sealing, leading to increased motor efficiency and reliability.
Implementation Method 1
a BLDC motor which is embedded inside the housing and rotates the housing around the motor shaft
Data Source
AI summary
Provided is a hub-type electric driving device including: a housing having a wheel formed in the shape of a cup, and a cover whose outer peripheral part is coupled to the opening of the wheel; a motor shaft having both end portions fixed on a body outside of the housing; first and second bearings provided respectively in through-holes formed in the centers of the wheel and the cover; and a BLDC motor embedded inside the housing and rotating the housing around the motor shaft. The BLDC motor includes: a rotor in which a back yoke and a magnet are stacked on a cylindrical inner wall of the wheel; and a stator whose outer peripheral part faces the magnet of the rotor while having an air gap therewith and whose central part is coupled to the outer circumference of the motor shaft.