Molded Motor Bracket Attachment via Integrated Resin Groove
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Solution Overview
Problem
Conventional molded motors require post-treatment cutting to form engagement grooves for bracket attachment, leading to size limitations and increased manufacturing complexity due to shavings and complex mold designs.
Innovation Solution
The motor integrates a connecting wire guide on the insulator with an arch-shaped inner surface and a V-shaped engagement recess on the outer shell, formed concurrently during resin molding, allowing for crimped bracket attachment without cutting, enhancing structural integrity and simplifying mold design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an engagement groove is formed by cutting after molding, then the bracket can be attached to the stator, but shavings are generated requiring post treatment and the motor size increases
Solution Approach 1:
The engagement groove is formed in advance during the resin molding process rather than cutting it after molding. The mold includes a groove-forming portion that creates the engagement groove on the outer peripheral surface of the stator while the resin is being molded, eliminating the need for subsequent cutting operations and reducing motor size.
Solution Approach 2:
The formation of the engagement groove is merged with the resin molding process. The groove-forming portion of the mold integrates the groove creation function into the molding operation, so that the engagement groove and the stator body are formed in a single process step, eliminating separate cutting operations.
2Ease of manufacture
If an engagement groove is formed by cutting after molding, then the bracket can be attached to the stator, but the manufacturing process becomes more complex with shavings requiring post treatment
Solution Approach 1:
The engagement groove is formed in advance during the resin molding process rather than cutting it after molding. The mold includes a groove-forming portion that creates the engagement groove on the outer peripheral surface of the stator while the resin is being molded, eliminating the need for subsequent cutting operations and reducing motor size.
Solution Approach 2:
The formation of the engagement groove is merged with the resin molding process. The groove-forming portion of the mold integrates the groove creation function into the molding operation, so that the engagement groove and the stator body are formed in a single process step, eliminating separate cutting operations.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
A molded motor includes an annular yoke part, a stator including a stator core having a plurality of teeth parts extending from an inner peripheral surface of the annular yoke part toward a center thereof, an insulator covering the stator core, an outer shell formed around the stator core and the insulator and made of resin, a rotor coaxially disposed at the center of the stator, a connecting wire guide provided on the insulator to stand in an axial direction of the stator core at a position corresponding to an engagement recess of an outer peripheral part of the outer shell, and a connecting wire guided by the connecting wire guide. A crimped part of a bracket adapted to be attached to an end face of the stator is engaged with the engagement recess when a part of a side end face of the bracket is crimped and secured.