Non-Circular Stator Geometry for Higher-Torque Motors
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Solution Overview
Problem
Existing electric motors face inefficiencies in rotation due to the shape and material characteristics of their magnetic components, limiting their performance and packaging flexibility.
Innovation Solution
The design of a motor with a non-circular stator featuring varying tooth lengths and coil windings, allowing for optimized flux flow and packaging by incorporating non-uniform air gaps and component receiving areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional circular stator with uniform teeth is used, then the motor structure is simple and easy to manufacture, but the torque output is limited and phase resistance is high
Solution Approach 1:
The patent applies asymmetry by designing a non-circular stator with teeth of varying lengths around the circumference. Specifically, teeth in certain angular positions extend further radially than others, creating an asymmetric magnetic path that optimizes flux distribution and increases torque output. This asymmetric geometry allows the motor to generate higher torque while maintaining manufacturing feasibility through standard forming processes.
Solution Approach 2:
The patent implements local quality by providing different tooth lengths at different locations around the stator circumference. Teeth are selectively extended in specific radial directions to create localized magnetic field enhancements where needed. This local variation in tooth geometry optimizes the magnetic flux distribution across the air gap, improving torque generation in critical regions without requiring complete redesign of the entire stator structure.
2Device complexity
If a conventional circular stator with uniform teeth is used, then the motor structure is simple, but the packaging flexibility is limited
Solution Approach 1:
The non-circular stator geometry with asymmetric tooth distribution provides enhanced packaging flexibility. The varied tooth lengths create natural spacing variations that allow for more efficient arrangement of surrounding components such as ball screws, bearings, and housing elements. This asymmetric configuration enables compact robotic joint designs where space optimization is critical, while the overall stator remains a single formed piece maintaining structural simplicity.
3Power
If teeth of varying lengths are used in the stator, then torque output is enhanced and phase resistance is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent changes the geometric parameter of tooth length to optimize motor performance. By varying the radial extent of teeth at different angular positions, the magnetic flux path is optimized to reduce phase resistance and enhance torque output. Despite this parameter variation, the stator can be manufactured as a single formed piece using conventional processes, balancing performance improvement with manufacturing feasibility.
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
Enhances torque output and reduces phase resistance while enabling efficient packaging of additional components, such as ball screws, in robotic applications.
Implementation Method 1
an electric current is passed through the coils, and a magnetic field is generated, which acts upon the magnets. When the magnetic field acts upon the magnets, one side of the rotating element is pushed and an opposing side of the rotating element is pulled, which thereby causes the rotating element to rotate relative to the stationary element.
Implementation Method 2
The teeth of the first set of teeth are longer in a radial direction from the rotor receiving area than the teeth of the second set of teeth
Data Source
AI summary
An apparatus includes a motor having a rotor; and a stator, where the rotor is located at least partially in a rotor receiving area of the stator, where the stator includes at least one coil winding and teeth, where the at least one coil winding is located on at least some of the teeth, where the teeth include a first set of the teeth and a second set of the teeth, where the teeth of the first set of teeth are longer in a radial direction from the rotor receiving area than the teeth of the second set of teeth.