Motor Stator Cover Structure to Block Rotor Gap Dust
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Solution Overview
Problem
Existing motor designs fail to effectively prevent powder dust, such as iron powder, from entering the gap between the rotor and stator, especially in environments with frequent vibration, leading to reduced efficiency and increased maintenance costs.
Innovation Solution
A motor design that includes a stator, rotor, and a cover formed mechanically integral with the insulator, where the cover closes the gap between the rotor and stator, reducing the entry of powder dust and improving motor efficiency by accurately managing the gap between the stator and bearing holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a gap is left between the rotor and stator for rotor rotation, then the rotor can rotate freely, but powder dust can enter the gap causing efficiency loss and maintenance issues
Solution Approach 1:
A cover member is introduced as an intermediary component between the rotor and stator. This cover member includes a closing portion that closes the gap between the rotor and stator, preventing powder dust entry while allowing rotor rotation through the closing portion's opening.
Solution Approach 2:
The cover member is divided into functional segments: a closing portion that seals the gap and a opening that allows rotor rotation. The insulator is also segmented with a cover formed integrally with it, creating distinct functional zones for insulation and dust prevention.
2Object-affected harmful factors
If the cover closes the gap between rotor and stator, then powder dust entry is reduced, but the gap management precision is required
Solution Approach 1:
The cover member is configured to automatically manage the gap between rotor and stator through its own structural design. The closing portion naturally maintains the appropriate gap distance without requiring external adjustment mechanisms, allowing the component to self-regulate the gap.
Solution Approach 2:
The cover member is pre-configured with the closing portion that establishes the correct gap distance before the motor operates. This preliminary structural arrangement ensures proper gap management is achieved during assembly without requiring precise post-assembly adjustments.
3Ease of manufacture
If the cover is formed mechanically integrally with the insulator, then the structure is simplified and manufacturing cost is reduced, but the cover must still perform its dust prevention function
Solution Approach 1:
The cover is formed mechanically integrally with the insulator, merging two components into one. This integration simplifies the overall structure, reduces the number of parts, and lowers manufacturing costs while the integrated cover maintains its dust prevention functionality through its closing portion design.
Solution Approach 2:
The integrated cover-insulator component performs multiple functions simultaneously: electrical insulation, dust prevention, and structural support. This multi-functional design eliminates the need for separate components, reducing complexity and manufacturing cost while maintaining all necessary functions.
Data Source
AI summary
A motor includes a stator, a rotor, and a cover. The rotor is disposed inside the stator with a gap left with respect to the stator. The rotor is provided to be rotatable with respect to the stator. The stator includes a plurality of coils, a plurality of teeth, and a coupling portion. Around the plurality of teeth, the plurality of coils are respectively arranged via an insulator. The coupling portion is located closer to the rotor than the plurality of coils. The coupling portion couples at least some adjacent ones of the plurality of teeth. The cover is formed mechanically integrally with the insulator. The cover is disposed to face at least a space inside the coupling portion along a rotational axis X of the rotor. The cover closes the gap.