Electric Motor End Cap with Partitioned Cavities for EMC
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Solution Overview
Problem
Existing electric motors lack sufficient space for mounting electromagnetic compatibility (EMC) components due to the presence of multiple components such as a printed circuit board (PCB), brushes, and a bearing in the end cap, making the motor complex and assembly time-consuming.
Innovation Solution
The electric motor design incorporates a support plate in the end cap that divides the interior space into two cavities, allowing for the PCB to be mounted in one cavity and brushes and EMC components like chokes and capacitors to be mounted in the other, with terminals and a connector for electrical connections, enabling efficient assembly and integration of EMC components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components (PCB, brushes, bearing) are mounted in the end cap, then the motor can function properly, but there is no space left for mounting EMC components
Solution Approach 1:
The end cap is divided into multiple cavities using a partition wall. The first cavity accommodates brushes and bearing, while the second cavity is dedicated to PCB and EMC components. This segmentation allows each component to be mounted in its designated space, resolving the space conflict while maintaining all motor functions.
2Adaptability or versatility
If an extra protection cap is added for mounting the PCB, then there is enough space for EMC components, but the motor becomes complex and assembly is time-consuming
Solution Approach 1:
The partition wall is integrally formed with the end cap as a single piece, eliminating the need for separate protection caps or additional mounting structures. The end cap itself is designed to contain multiple cavities, merging the functions of protection, mounting, and organization into one component, thereby reducing overall complexity and assembly steps.
3Adaptability or versatility
If an extra protection cap is added for mounting the PCB, then there is enough space for EMC components, but assembly becomes time-consuming
Solution Approach 1:
The partition wall is pre-integrated into the end cap during manufacturing, creating ready-made cavities for component mounting. This preliminary structuring eliminates the need for additional assembly steps to create mounting spaces, allowing PCB and EMC components to be directly installed in their designated cavities, thereby accelerating the assembly process.
Data Source
AI summary
An electric motor includes a stator, a rotor and an end cap. The stator includes a housing and magnets attached to an inner surface of the housing. The housing has an open end closed by the end cap. The rotor includes a shaft, an armature and a commutator fixed to the shaft. The end cap includes a cover case, a support plate integrally formed in the cover case, brushes, a bearing and a printed circuit board mounted in the cover case. The support plate divides the interior space of the cover case into a first cavity and a second cavity. The brushes are mounted in the first cavity, the bearing is mounted on the support plate, and the printed circuit board is mounted in the second cavity.