Integrated Rotor Pinion Assembly for Simpler Electric Motors
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Solution Overview
Problem
The assembly of electric motors with stators and rotors is complex due to the plurality of parts involved, making the process difficult and time-consuming.
Innovation Solution
The integration of a pinion gear with the rotor body as a single piece, along with a stator core and windings, and the use of powder metallurgy processes such as sintering and injection molding to form a solid magnetic body within the rotor assembly, reducing part count and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate parts are used for stator and rotor assembly, then functional requirements are met, but assembly complexity increases and manufacturing becomes difficult
Solution Approach 1:
The patent merges the rotor body and pinion gear into a single integral rotor assembly, and the stator core and transmission housing into a single integral stator assembly. This combining of previously separate parts directly reduces assembly complexity and manufacturing difficulty while maintaining all necessary functions.
Solution Approach 2:
The rotor assembly serves multiple functions: it acts as both the rotating electromagnetic component and the pinion gear for transmission. Similarly, the stator assembly functions as both the magnetic field generator and the transmission housing. This multi-functionality reduces the total number of parts needed.
2Manufacturing precision
If traditional manufacturing processes are used for rotor magnets, then material properties are achieved, but manufacturing time and complexity increase
Solution Approach 1:
The magnetic body is formed within the rotor assembly during the initial powder metallurgy manufacturing process, rather than being added as a separate subsequent step. The cavities for the magnetic body are prepared in advance during rotor body fabrication, and the magnetic material is then formed in-place using sintering or injection molding, eliminating separate manufacturing operations.
Solution Approach 2:
The patent employs powder metallurgy processes with controlled sintering parameters to form the magnetic body directly within the rotor assembly. By adjusting sintering temperature, pressure, and atmosphere, the magnetic material achieves required properties while being formed in a single integrated process rather than through multiple traditional manufacturing steps.
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 approach simplifies the assembly process, reduces the length and complexity of the motor, and provides material savings, resulting in a more efficient and cost-effective electric motor design.
Implementation Method 1
processing the magnetic material, using one or more of a sintering, bonding, or injection molding process, to form a solid magnetic body within the cavity
Implementation Method 2
processing the magnetic material, using one or more of a sintering, bonding, or injection molding process, to form a solid magnetic body within the cavity
Data Source
AI summary
The disclosure provides, in one aspect, an electric motor comprising a stator and a rotor assembly including a rotor body and a pinion gear integrally formed as a single piece with the rotor body.