Motor Rotor Holder Segmentation for Precision
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Solution Overview
Problem
Conventional motors face challenges in maintaining positioning accuracy and strength due to integration issues between the rotor core, magnet, and frame during resin molding, leading to potential deformation and reduced strength.
Innovation Solution
The motor design incorporates a rotor holder with a holder lid portion and tubular portion that houses the magnet, rotor core, and spacer, allowing for precise positioning and increased rigidity through a modular structure that reduces stress on the stator core and circuit board, enhancing torque and power efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the frame, rotor core, and magnet are integrally formed by resin molding, then the rotor structure is simplified and manufacturing is easier, but positioning accuracy of the rotor core and magnet deteriorates and strength is reduced
Solution Approach 1:
The rotor is divided into separate components: the frame (121), rotor core (13), and magnets (14) are manufactured independently and then assembled together using the rotor holder (12), rather than being integrally molded as a single piece. This segmentation allows each component to be precisely manufactured and positioned separately while maintaining manufacturing efficiency.
2Ease of manufacture
If the frame, rotor core, and magnet are integrally formed by resin molding, then the rotor structure is simplified, but strength of the rotor is reduced
Solution Approach 1:
The rotor components are segmented and assembled using a dedicated rotor holder (12) that provides structural support and strength. The holder includes a holder tubular portion (122) and holder lid portion (121) that collectively strengthen the rotor assembly while allowing independent manufacturing of each component.
3Ease of manufacture
If resin molding is used to integrate the frame, rotor core, and magnet, then assembly is simpler, but deformation during curing occurs and positioning accuracy deteriorates
Solution Approach 1:
The components are segmented and assembled in a predetermined sequence using the rotor holder as a framework, avoiding the curing deformation issues associated with resin molding. The holder provides a stable structure that maintains dimensional accuracy during assembly.
Solution Approach 2:
The rotor holder (12) is prepared in advance with positioning features such as the holder first surface (123) and holder second surface (124) that establish precise positions for the rotor core and magnets before final assembly, preventing positioning errors that would occur with post-curing deformation.
4Manufacturing precision
If a modular rotor holder structure is used to house the magnets and rotor core, then positioning accuracy and strength are improved, but device complexity increases
Solution Approach 1:
The holder tubular portion (122) and holder lid portion (121) are merged to form an integrated rotor holder structure that houses both the magnets and rotor core. This merging approach provides precise positioning and structural strength while minimizing the number of separate components, thus controlling device complexity.
Data Source
AI summary
A motor includes a rotor with one or more magnets, a rotor core holding the one or more magnets, a spacer that contacts the one or more magnets, and a rotor holder. The rotor holder includes a holder lid portion and a holder tubular portion in a tubular shape extending to one side in the axial direction from a radially outer edge of the holder lid portion. The holder lid portion includes a holder first surface that extends radially inward from an inner surface of the holder tubular portion, a holder second surface that extends radially and is radially inward of the holder first surface and on the other side in the axial direction, and a connecting surface connecting the holder first surface and the holder second surface.