Motor Support Protuberance Assembly
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Solution Overview
Problem
Existing motor designs require high accuracy in the dimensions of support members and holders to securely position and assemble components, which can be challenging and costly, especially when integrating with electric power steering systems.
Innovation Solution
The motor design incorporates a support member with first and second protuberances, where the first protuberance is closely positioned within the holder's through hole, and the second protuberance has a clearance, allowing for easier assembly and reduced dimensional control requirements, particularly by using an insulating material for the support member and a holder with through holes for holding the support member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high accuracy dimensional control is implemented for the through hole and support member, then the assembly reliability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The support member is segmented into multiple protuberances (first and second protuberances) with different functions. The first protuberance provides positioning function with close fit to the through hole, while the second protuberance provides support function with clearance. This segmentation allows different dimensional requirements for different parts, reducing overall manufacturing complexity while maintaining assembly reliability.
Solution Approach 2:
Different regions of the support member are given different dimensional characteristics. The first protuberance has dimensions optimized for precise positioning (close fit), while the second protuberance has dimensions optimized for support with tolerance (clearance). This local differentiation of quality reduces the need for high precision across the entire component, lowering manufacturing complexity.
2Stability of the object's composition
If the support member is tightly fitted in the through hole, then the positional stability is improved, but the assembly difficulty increases
Solution Approach 1:
The support function is segmented into two separate protuberances: the first protuberance handles positioning (providing stability through close fit), while the second protuberance handles support (allowing easier assembly through clearance). This functional segmentation resolves the contradiction between stability and ease of assembly.
Solution Approach 2:
The second protuberance acts as an intermediary that provides clearance space, facilitating easier insertion and assembly of the support member into the holder, while the first protuberance ensures the necessary positional stability is achieved.
Data Source
AI summary
A motor includes a rotor including a shaft extending in an axial direction, a stator surrounding a radially outer portion of the rotor, a support into which the conductor is inserted, the support being made of an insulating material, and a holder including through holes to hold the support, in which the support includes the first and second protuberances at least a portion of which is located in the through hole, the first and second protuberances being provided at intervals, and a base portion connecting the first and second, protuberances, and in which at least a portion of each of facing regions of a side surface of the first protuberance is close to the holder, and the second protuberance has a clearance with respect to the holder.