Composite Motor Housing Structure for Lower Cogging Torque
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Solution Overview
Problem
Motors face issues with housing cracks, cogging torque, and friction torque, which affect performance and manufacturing costs, and require additional fastening components for the bearing housing.
Innovation Solution
A motor design with a housing composed of two regions, one made of steel and the other of an aluminum alloy, where the steel region is in contact with the stator core to reduce cogging torque and friction torque, and a groove system to prevent foreign matter and water ingress, eliminating the need for separate fastening components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a die casting method is used to manufacture the housing, then both the bearing plate and mounting structure can be molded in one piece, but cracks are generated in the housing
Solution Approach 1:
The housing is divided into two separate parts: a first housing made of aluminum alloy and a second housing made of steel. This segmentation allows each part to be manufactured using appropriate methods without causing cracks, while still achieving the functional benefits of an integrated structure.
Solution Approach 2:
The housing uses a composite structure combining aluminum alloy (first housing) and steel (second housing). This allows the aluminum alloy to provide lightweight properties and the steel to provide structural strength and crack resistance, resolving the contradiction between ease of manufacture and housing integrity.
2Device complexity
If the stator and rotor are disposed with spaced teeth to form slot opens, then the motor structure is simplified, but cogging torque and friction torque increase
Solution Approach 1:
The patent changes the material parameter of the housing from aluminum alloy to steel in the second housing. This material parameter change reduces the permeability difference between the stator and air in the slot opens, thereby reducing cogging torque while maintaining the simplified spaced teeth structure.
3Strength
If a separate fastening member is used to couple the bearing housing and housing, then the coupling is secure, but manufacturing costs increase
Solution Approach 1:
The first housing and second housing are directly coupled together without using separate fastening members. The coupling interface between the two housing parts provides sufficient mechanical strength, eliminating the need for additional fastening components and reducing manufacturing costs.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical support, couples the bearing housing and mounting structure, and eliminates the need for separate fastening members. This multi-functionality reduces the number of components and simplifies manufacturing.
Data Source
AI summary
The present invention may provide a motor including a shaft, a rotor coupled to the shaft, a stator disposed to correspond to the rotor, and a housing configured to accommodate the stator, wherein the housing includes a first housing, a second housing, and a first member, the first housing includes a first contact surface, the second housing includes a second contact surface of which at least a partial region is in contact with the first contact surface, a groove portion is positioned between the first contact surface and the second contact surface to be exposed to an outside of the housing, and the first member is disposed in the first housing to cover the groove portion.