Electric Motor Support Body for Precise Stator Positioning
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Solution Overview
Problem
Conventional electric motors face inefficiencies due to bulky, heavy, and expensive stator cores that cause magnetic saturation and reduce performance, as they need to be robust and precisely positioned, leading to increased size, weight, and manufacturing costs.
Innovation Solution
A compact, cylindrical support body acts as a cartridge for the rotor assembly, allowing slotted stator elements to maintain precise positioning without structural roles, enabling smaller, lighter motor design, improved magnetic interaction, and efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stator cores are made robust and to very high tolerance to achieve accurate positioning, then positioning precision is improved, but stator cores become bulky, heavy and expensive to manufacture
Solution Approach 1:
The stator assembly is divided into multiple individual stator elements (typically three) that are separately manufactured and then assembled around the rotor assembly. Each stator element is a simpler, lighter component that can be manufactured to standard tolerances, yet collectively they provide the necessary structural support and magnetic function without requiring a single bulky, high-tolerance stator core
Solution Approach 2:
The support body is extracted as a separate structural component from the stator core. This support body provides the mechanical framework and positioning functions, while the stator elements focus solely on their magnetic and electrical functions. This separation allows each component to be optimized independently, reducing overall weight while maintaining positioning precision
2Manufacturing precision
If stator cores are made robust and to very high tolerance to achieve accurate positioning, then positioning precision is improved, but manufacturing cost increases
Solution Approach 1:
Dividing the stator into separate elements allows each to be manufactured using standard, cost-effective processes rather than requiring expensive high-precision machining of a single large core. The segmented approach enables modular assembly and reduces tooling costs
Solution Approach 2:
Extracting the support body as a separate component shifts the positioning function to a structural element that can be manufactured independently at lower cost. The stator elements can then be produced using conventional winding and assembly processes, reducing overall manufacturing complexity and cost
3Manufacturing precision
If stator cores include mounting features such as through holes and cut away portions, then structural positioning is improved, but magnetic saturation occurs reducing efficiency and performance
Solution Approach 1:
The mounting features and structural positioning functions are extracted from the stator core and transferred to the separate support body. This allows the stator core to maintain its magnetic integrity without holes or cutaways that would cause saturation, while the support body provides all necessary mechanical mounting and positioning features
Solution Approach 2:
Separating the structural support function from the magnetic core function eliminates the need for compromising features in the stator core. The segmented design allows the core to be a complete, solid magnetic structure optimized for magnetic performance, while mounting requirements are handled by the non-magnetic support body
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 minimizes motor size and weight, reduces manufacturing complexity, and enhances efficiency by allowing for precise positioning and effective cooling, while using lighter materials to lower costs.
Implementation Method 1
a rotor assembly comprising a permanent magnet... a stator assembly... Each of the plurality of openings is configured to receive one of the plurality of stator elements
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
An electric motor comprising: a stator assembly; a rotor assembly; and a support body. The stator assembly comprises a plurality of stator elements, and the rotor assembly comprises a shaft to which is mounted at least a first and a second bearing mounted either side of a permanent magnet. The support body comprises an elongate central part, and first and second bearing seats positioned axially at opposite ends of the elongated central part to each other, and the elongate central part defines a plurality of openings each configured to receive one of the plurality of stator elements.