Insert-Molded Hollow Shaft Motor to Eliminate Assembly Tolerances
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional hollow shaft motors face issues such as assembly tolerances leading to concentricity problems, noise and vibration during operation, and moisture penetration due to complex manufacturing processes involving separate components and post-processes.
Innovation Solution
A hollow shaft motor design that integrates the stator assembly into a motor housing through insert injection molding, ensuring concentricity, reducing noise and vibration, and preventing moisture ingress by forming the motor housing around the stator assembly using resin molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate components (stator assembly, motor housing, upper cover) are assembled using conventional manufacturing methods, then manufacturing flexibility is maintained, but assembly tolerances cause concentricity problems and require additional post-processing steps
Solution Approach 1:
The patent merges the stator assembly and motor housing into a single integrated component formed by insert injection molding. The stator core, coils, and housing are molded together in one manufacturing process, eliminating the need for separate assembly operations and ensuring perfect concentricity between rotating and stationary parts.
Solution Approach 2:
The insert injection molding process serves multiple functions simultaneously: it forms the housing structure, positions the stator assembly with precise concentricity, and creates integrated mounting features. This multi-functional approach replaces multiple separate manufacturing and assembly operations.
2Object-generated harmful factors
If conventional assembly methods with multiple components are used, then manufacturing process adaptability is maintained, but assembly tolerances generate noise and vibration during motor operation
Solution Approach 1:
By combining the stator assembly and motor housing into a single molded component, the patent eliminates gaps, misalignments, and loose connections that generate noise and vibration. The integrated structure ensures precise positioning of all internal components, preventing operational disturbances.
3Reliability
If separate components are assembled conventionally, then manufacturing flexibility is maintained, but assembly gaps allow moisture and foreign substances to penetrate into the stator assembly
Solution Approach 1:
The integrated molding process creates a seamless structure where the stator assembly is fully enclosed within the housing without assembly gaps. This monolithic construction inherently prevents moisture and foreign substance penetration, eliminating the need for separate sealing components.
4Ease of manufacture
If post-process steps are added to form bearing insertion spaces, then bearing installation is enabled, but the number of processing steps increases
Solution Approach 1:
The insert injection molding process performs preliminary actions by pre-forming bearing insertion spaces and mounting features during the primary molding operation. This eliminates the need for subsequent post-processing steps to create these features, reducing the total number of manufacturing operations.
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
Simplifies manufacturing, eliminates assembly tolerances, minimizes noise and vibration, and prevents moisture ingress, thereby ensuring reliable operation of the brake system.
Implementation Method 1
a motor housing 20 formed around the stator assembly 10 by resin molding
Data Source
AI summary
A hollow shaft motor according to the present invention comprises: a stator assembly 10 including: a stator 11 comprising a stator core 110, an upper insulator 111 coupled to an upper part of the stator core 110, a lower insulator 112 coupled to a lower part of the stator core 110, and a coil 113 wound around teeth of the stator 11; and a busbar unit 12 coupled to an upper part of the stator 11; and a motor housing 20 formed around the stator assembly 10 by resin molding, wherein the busbar unit 12 comprises a plurality of busbars 120 and a pre-mold 121 to which the busbars 120 are fixed.