Open Connection Ring Layout for Compact Motor Coil Assembly
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Solution Overview
Problem
Motor assemblies in handheld devices face challenges with reduced size and weight, leading to difficulties in stator coil winding and increased air resistance due to connection members, which also result in low production yield and separation issues.
Innovation Solution
A connection ring with a ring-shaped body and radial phase coil connection portions is used, allowing for efficient production and easy connection of stator coils, while a bracket and protrusion system ensures stable coupling and reduced air resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the outer size of the motor assembly is reduced, then the size and weight of the device are reduced, but the distance between stator teeth is narrowed making coil winding difficult
Solution Approach 1:
The stator core is divided into separate teeth and yoke components. The teeth are manufactured separately with coil windings already in place, then assembled to the yoke. This segmentation allows coil winding to be performed on individual teeth rather than requiring tight spacing between all stator teeth, solving the manufacturing difficulty while maintaining compact overall size.
2Ease of manufacture
If a connection member is used to connect neutral lines of stator coils, then coil connection is achieved, but air movement resistance increases due to the connection member being disposed in the air flow path
Solution Approach 1:
The connection member is extracted from the air flow path and repositioned to the outer periphery of the stator, where it does not interfere with air movement. The neutral line connections are made at this peripheral location rather than within the central air flow channel, eliminating the harmful air resistance effect while maintaining electrical connection functionality.
3Ease of manufacture
If a plate-shaped electrical conductor is used to form the connection member, then electrical connection is achieved, but a relatively large amount of scrap material is generated
Solution Approach 1:
The connection member is formed by winding a strip-shaped conductor in a circular pattern around the stator outer periphery, creating a three-dimensional ring structure. This dimensional transformation from a flat plate shape to a wound ring structure allows more efficient utilization of the base material, reducing scrap generation while maintaining the electrical connection function.
4Productivity
If the connection ring is designed with an opening and radial protrusions, then production yield increases, but the structure becomes more complex
Solution Approach 1:
The connection ring is segmented with an opening rather than being a complete circle, and includes radial protrusions that extend toward the stator. This segmentation allows multiple connection rings to be nested or arranged more efficiently during production, increasing the number of units that can be manufactured per unit area of base material, thereby improving production yield despite the increased structural complexity.
Data Source
AI summary
The present invention relates to a motor assembly connection ring and a manufacturing method therefor, and a motor assembly. A motor assembly of the present invention comprises: a housing; an impeller provided in the housing; a stator provided in the housing and having a plurality of phase coils; a rotor which has a rotation shaft connected to the impeller and is disposed to be rotatable with respect to the stator; and a connection ring formed of an electric conductor and connected to one ends of the plurality of phase coils, wherein the connection ring includes: a ring-shaped body having an open side; and a plurality of phase coil connection units respectively extending in a radial direction from the body and respectively connected to ends of the plurality of phase coils. Accordingly, the production yield (stamping yield) of the connection ring can be increased.