Spoke-Type Motor Rotor Coupling Structure for High-Speed Durability
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Solution Overview
Problem
The spoke type permanent magnet motor's rotor cores are prone to separation from the molded body during high-speed rotation due to the low strength of the molded body, leading to durability issues.
Innovation Solution
A motor design featuring a stator with circumferentially arranged stator cores and coils, a rotor with circumferentially arranged rotor cores and magnets, and a molded body with coupling ribs and grooves that securely attach the rotor cores and magnets, preventing separation through centrifugal force during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the molded body is used to support rotor cores and magnets, then the rotor structure is simplified and manufacturing is easier, but the molded body has low strength and may be damaged during high-speed rotation causing rotor core separation
Solution Approach 1:
The patent uses a composite structure combining the molded body with additional support elements (rotor core support plates and coupling ribs) to achieve both ease of manufacture and sufficient strength. The molded body provides the basic structure while the support plates and ribs reinforce critical areas to prevent rotor core separation during high-speed rotation.
2Device complexity
If the molded body has low strength, then manufacturing complexity is reduced, but durability is compromised as the molded body may be damaged during rotation leading to rotor core separation
Solution Approach 1:
The patent segments the support function by introducing separate rotor core support plates and coupling ribs that work together with the molded body. This segmentation allows each component to be optimized for its specific function while maintaining overall manufacturing simplicity and improving durability through distributed structural support.
3Strength
If coupling ribs are added to the molded body, then the strength and coupling ability are improved, but the device complexity increases
Solution Approach 1:
The patent merges the coupling rib structure directly into the molded body through integral forming, where the coupling ribs are formed as part of the molded body structure rather than as separate components. This merging approach improves strength and coupling ability while minimizing device complexity by eliminating additional assembly steps and components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the durability of the motor by firmly coupling the rotor cores to the molded body, preventing separation during high-speed rotation and maintaining magnetic flux concentration for efficient power generation.
Implementation Method 1
A motor includes a stator including a plurality of stator cores arranged in a circumferential direction, and coils respectively wound around the stator cores, and a rotor rotatably arranged inside or outside the stator
Implementation Method 2
The rotor is rotated by a force exerted between a magnetic filed and current flowing through a coil
Implementation Method 3
a coupler including coupling ribs outwardly extending from an outer circumferential surface of the bridge in a radial direction of the rotor, and coupling grooves formed at inner ends of the rotor cores supported by the bridge, to receive the coupling ribs, respectively
Data Source
AI summary
A motor having a structure capable of achieving an enhancement in durability and a washing machine, to which the motor is applied. The motor includes a stator including a plurality of stator cores arranged in a circumferential direction, and coils respectively wound around the stator cores, and a rotor rotatably arranged inside or outside the stator. The rotor includes a plurality of rotor cores arranged in a circumferential direction of the rotor, a plurality of magnets each disposed between neighboring ones of the rotor cores, a molded body having a bridge to support the plurality of rotor cores and the plurality of magnets, and a coupler including coupling ribs outwardly extending from an outer circumferential surface of the bridge in a radial direction of the rotor, and coupling grooves formed at inner ends of the rotor cores supported by the bridge, to receive the coupling ribs, respectively.