Nested Motor Housing Closures for Compact Rotor Support
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Solution Overview
Problem
Existing electric motor housings are not optimized for compactness, which is crucial in mobile environments, as their volume is a key parameter that requires constant optimization.
Innovation Solution
The design includes a tubular wall with closures at opposite axial ends, where at least one closure is separately formed with a radially inner portion and outer flange that minimizes internal space, allowing for efficient use of the housing's interior for components like wiring and electronic circuits, and features a non-rotationally symmetric through hole to securely support the rotor with minimal space occupation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional housing structures are used, then assembly is simplified, but volume is not optimized for compactness
Solution Approach 1:
The housing is divided into a tubular wall and separately formed closures that can be assembled independently. The closure includes a radially inner portion and a radially outer flange that can be separately manufactured and then assembled to the tubular wall, allowing each component to be optimized independently for volume and assembly ease.
Solution Approach 2:
The radially outer flange is designed to extend from the radially inner portion and press against the radially inner surface of the tubular wall, creating a nested assembly structure. This nesting allows the closure components to be inserted and secured within the tubular wall structure, minimizing overall housing volume while maintaining assembly simplicity.
2Reliability
If additional fixing means are used, then rotor support is more secure, but device complexity increases
Solution Approach 1:
The radially outer flange is designed to automatically press against the radially inner surface of the tubular wall through its own structural configuration when assembled. This self-service mechanism provides secure rotor support through the geometric arrangement of the flange and tubular wall interface, eliminating the need for additional separate fixing means such as screws or clips.
3Volume of moving object
If internal space is not minimized, then assembly is easier, but housing compactness is reduced
Solution Approach 1:
The radially outer flange is pre-formed as an integral part of the closure structure, with its pressing surface already positioned to engage the tubular wall. This preliminary configuration of the flange geometry ensures that when the closure is assembled, the space-minimizing contact is automatically achieved without requiring complex assembly operations or additional adjustments.
Data Source
AI summary
An electric motor includes a housing with a tubular wall extending in an axial direction of the housing and a closures positioned at opposite axial ends of the tubular wall, a stator fixedly mounted inside of the housing, a rotor rotatably mounted inside of the housing, and a bearing rotatably supporting the rotor. At least one of the closures includes a rotor supporting portion. The rotor supporting portion includes a through hole configured to receive a portion of the rotor. The through hole has a triangular or polygonal shape, and a radius of an inscribed circle of the triangular or polygonal shape of the through hole is larger than a radius of the portion of the rotor received in the through hole.