Magnet Holder Locking Structures for Electric Motor Stator
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Solution Overview
Problem
The existing methods for attaching magnets to the stator housing in electric motors are complex, time-consuming, and prone to failure due to glue aging at high temperatures, leading to magnet detachment.
Innovation Solution
A stator design featuring a magnet holder with locking structures and a flux ring that securely fixes elongate plate-shaped magnets, using a combination of locking surfaces, wedge-shaped ends, and a retaining ring to prevent inward movement and ensure magnetic pole alignment, with optional plastic injection for additional fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnets are adhered to the stator housing via glue, then the magnet attachment process is simple, but the magnets may detach from the stator housing when the motor operates at high temperature for a long time
Solution Approach 1:
The magnet holder is divided into multiple locking structures, with each locking structure having a pair of concave locking surfaces that independently secure adjacent magnets. This segmentation allows each magnet to be firmly locked by dedicated locking surfaces, preventing detachment under high temperature operation while maintaining a relatively simple overall attachment process.
Solution Approach 2:
The patent replaces the chemical bonding method (glue adhesion) with a mechanical locking system consisting of locking structures and locking surfaces. This mechanical substitution eliminates the aging and detachment problems associated with glue at high temperatures, providing reliable and durable magnet fixation without sacrificing manufacturing simplicity.
2Reliability
If a magnet holder with locking structures is used to fix magnets, then the magnet attachment reliability is improved, but the device complexity increases
Solution Approach 1:
The magnet holder integrates multiple functions into a single component: it combines the retaining function (holding magnets in place), the locking function (preventing outward movement via locking structures), and the locating function (ensuring proper positioning relative to the stator housing). This merging reduces the need for separate components and simplifies the overall device structure while maintaining high reliability.
Solution Approach 2:
The magnet holder is designed as a multi-functional component that simultaneously performs retention, locking, and locating functions for multiple magnets. The locking structures serve multiple purposes by providing both mechanical retention and positional alignment, reducing the total number of parts needed and simplifying the overall device complexity.
3Productivity
If locking structures are added to the magnet holder, then the manufacturing time is reduced compared to glue application, but the manufacturing precision requirements increase
Solution Approach 1:
The locking structures and locking surfaces are pre-formed during the molding or manufacturing process of the magnet holder and magnets, respectively. This preliminary action eliminates the need for time-consuming manual glue application and alignment operations, significantly improving productivity. The precision requirements are built into the manufacturing process rather than requiring post-assembly adjustments.
Solution Approach 2:
The patent specifies that the side surfaces of the magnets conform to the locking surfaces of the magnet holder, creating a precise geometric relationship. By changing the geometric parameters (concave shape, surface profile) of the locking structures, the design achieves both rapid assembly and high precision fitting, allowing for efficient manufacturing while maintaining strict dimensional control.
Data Source
AI summary
A stator includes a housing made of magnetically conductive material, a plurality of magnets fixed to the stator housing; and a magnet holder attached to one end of the housing for fixing the magnets to the stator housing. The magnet holder includes a body and a plurality of locking structures extending from the body. Each magnet is locked between two adjacent locking structures. A plurality of cut-outs is formed in the stator housing, and a plurality of projections is formed on the body of the magnet holder and engaged with the cut-outs. Each locking structure includes a wedge-shaped inner end inwardly abutting against respective magnets to prevent the magnets from moving inwardly.