Power Tool Motor Stator Assembly With Integrated Heat Sink Alignment
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Solution Overview
Problem
Existing power tools with electric motors face challenges in efficient heat dissipation and proper alignment during assembly, which can lead to reduced performance and increased manufacturing complexity.
Innovation Solution
The electric motor assembly includes a stator assembly with an annular stator body and windings, a rotor assembly, a circuit board, and a heat sink positioned between the stator assembly and the circuit board. The components are designed with specific angular spacings and attachment mechanisms to ensure proper alignment and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat sink is added between the stator assembly and circuit board, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The heat sink is integrated with the stator assembly and circuit board through direct thermal contact, combining multiple components into a unified thermal management system. The heat sink serves dual purposes: cooling the circuit board and providing a mounting surface for the stator assembly, thereby reducing the need for separate mounting structures.
Solution Approach 2:
The heat sink performs multiple functions simultaneously: it acts as a thermal management component for dissipating heat from the circuit board, a structural support element for mounting the stator assembly, and a thermal pathway conductor. This multi-functionality reduces the overall component count and simplifies the device architecture.
2Manufacturing precision
If specific angular spacings and attachment mechanisms are designed for proper alignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The attachment mechanisms incorporate asymmetric features such as positioned protrusions and corresponding recesses that provide unique alignment orientations. This asymmetry ensures that components can only be assembled in the correct orientation, guaranteeing proper alignment without requiring complex adjustment procedures or additional alignment tools.
Solution Approach 2:
The attachment mechanisms are pre-configured with specific angular spacings and geometric features during the design and manufacturing phase. This preliminary action ensures that when components are assembled, the alignment is automatically achieved through the pre-established geometric relationships, eliminating the need for post-assembly alignment adjustments.
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
This design ensures proper alignment of the motor components during assembly, improving manufacturability, and enhances heat dissipation through the heat sink, leading to improved motor performance and reliability.
Implementation Method 1
a heat sink positioned between the stator assembly and the circuit board. The heat sink is in thermal contact with the circuit board
Data Source
AI summary
An electric motor assembly includes a circuit board, a rotor assembly, and a stator assembly having a first end coupled to the circuit board and a second end opposite the first end. The stator assembly also includes an annular stator body having a plurality of inwardly projecting teeth. The stator assembly further includes windings wrapped about the stator body to form a plurality of coils. The stator assembly also includes a terminal coupled to an outer periphery of the stator body and extending longitudinally between the first end and the second end. The terminal is coupled to the circuit board at the first end and is coupled to the windings at the second end to electrically connect the windings to the circuit board. The terminal is molded to an attachment member, and the attachment member is molded to the outer periphery of the stator body.