Motor Rotor Shaft Alignment via Asymmetric Protrusions
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Solution Overview
Problem
The existing motor designs face challenges in preventing slipping between the shaft and rotor during assembly, aligning the shaft and rotor in the rotational direction, and aligning the shaft with the rotation detector, as well as facilitating the attachment of magnets to the shaft.
Innovation Solution
The motor design incorporates a rotor with grooves on its core and a shaft with protrusions and blades that fit into these grooves, allowing for precise alignment and preventing slipping, while also featuring a blade portion with guide protrusions and grooves to simplify the assembly process and magnet attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shaft and rotor are assembled without alignment features, then the assembly process is simple, but slipping occurs between the shaft and rotor in the rotational direction
Solution Approach 1:
The invention introduces asymmetric alignment features (protrusions on the shaft fitting into grooves on the rotor) that create a unique rotational orientation. This asymmetric design prevents slipping in the rotational direction while maintaining assembly simplicity, as the features guide proper alignment during assembly rather than requiring complex alignment procedures.
Solution Approach 2:
The alignment features (protrusions and grooves) are pre-formed on the shaft and rotor during manufacturing. This preliminary action ensures that when assembly occurs, the components naturally align in the correct rotational position without requiring additional alignment steps or adjustments during the assembly process.
2Reliability
If alignment features are added to the shaft and rotor, then rotational slipping is prevented, but the assembly process becomes more difficult
Solution Approach 1:
The asymmetric protrusion-groove design provides self-aligning characteristics that actually simplify the assembly process. The features guide the rotor onto the shaft in the correct rotational position, eliminating the need for complex alignment procedures or specialized tools, thus reducing assembly difficulty while ensuring rotational stability.
Solution Approach 2:
The alignment features are designed to self-align the shaft and rotor during assembly. The protrusions on the shaft fit into the grooves on the rotor, automatically establishing the correct rotational relationship without requiring external alignment tools or complex procedures, making the assembly process easier rather than more difficult.
3Device complexity
If magnets are directly attached to the shaft, then the structure is simple, but it is difficult to attach magnets using a device due to the rotation detector
Solution Approach 1:
The invention segments the shaft structure by adding a flange with a flat upper surface, creating a dedicated mounting platform for magnets. This segmentation separates the magnet attachment function from the rotational detection function, allowing magnets to be easily attached to the flange surface without interference from the rotation detector positioned elsewhere on the shaft.
Solution Approach 2:
The invention moves the magnet attachment location to a different dimensional space by adding a flange extending perpendicular to the shaft axis. The flat upper surface of the flange provides a new two-dimensional mounting surface that is spatially separated from the rotation detector, enabling easy magnet attachment in this new dimension without interfering with the rotation detection mechanism.
Data Source
AI summary
The present invention may provide a motor including a housing, a stator disposed inside the housing, a rotor disposed inside the stator, and a shaft coupled to the rotor, wherein the rotor includes a rotor core and magnets including a plurality of unit magnets coupled to an outer circumferential surface of the rotor core, the rotor core includes grooves disposed at a boundary between an inner circumferential surface and an upper surface of the rotor core, the shaft includes a first body, a plurality of blades extending outward from an upper surface of the first body, and a protrusion extending downward from a lower surface of the first body, and a side edge of the blade is positioned at a lateral center of the unit magnet when the protrusion is disposed in the groove.