Outer Rotor Motor Bearing Pocket and PCBA Integration
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Solution Overview
Problem
Existing outer rotor electric motors face challenges in efficiently integrating a stator assembly within a rotor body while maintaining effective bearing support and electrical connectivity for optimal torque output and power transmission.
Innovation Solution
The design incorporates a rotor assembly with a rotor shaft and magnets, a stator assembly with a stator core and windings, and a bearing system with an outer and inner race, where the stator core defines a central bore and bearing pocket to support the rotor shaft, and includes a printed circuit board assembly for position sensing and commutation, with a modular adapter for secure coupling to a gear case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the stator assembly is integrated within the rotor body in an outer rotor motor design, then the motor achieves compact structure and efficient power transmission, but the bearing support and electrical connectivity become more complex to implement effectively
Solution Approach 1:
The stator assembly is integrated within the rotor body, merging two previously separate components into a unified structure. The stator core assembly is positioned concentrically within the rotor body, with the rotor shaft extending through the stator core assembly, creating a compact outer rotor motor design that reduces overall motor size while maintaining functional separation of components.
Solution Approach 2:
The stator core assembly is nested within the rotor body, with the rotor shaft passing through the stator core assembly. The bearing is positioned within the stator core assembly, and the printed circuit board assembly is mounted on the stator core assembly, creating a nested arrangement of components that maximizes space utilization and achieves compact dimensions.
2Reliability
If the stator core assembly defines a central bore and bearing pocket to support the rotor shaft, then bearing support is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The stator core assembly is divided into functional segments: a central bore for receiving the rotor shaft, a bearing pocket for housing the bearing, and mounting features for the printed circuit board assembly. This segmentation allows each feature to be optimized for its specific function while maintaining overall manufacturing feasibility through modular construction.
Solution Approach 2:
The stator core assembly incorporates localized features with specific geometric properties: the central bore provides precise rotational alignment for the rotor shaft, the bearing pocket provides controlled support for the bearing, and the printed circuit board mounting area provides electrical connectivity. Each local region is designed with quality characteristics optimized for its specific function.
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 configuration enhances the integration of the stator within the rotor, improves bearing support, and facilitates efficient power transmission and electrical connectivity, leading to improved motor performance and reliability.
Implementation Method 1
a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body
Implementation Method 2
The rotor rotates relative to the stator to provide a torque output of the motor
Data Source
AI summary
An electric motor includes a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received within the rotor body. The stator assembly includes a stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount, the stator core assembly defining a central bore that receives the rotor shaft and the stator support portion. The electric motor also includes a bearing having an outer race and an inner race, the outer race being supported by the stator core assembly, and the inner race supporting the rotor shaft for rotation relative to the stator assembly. The stator core assembly further defines a bearing pocket adjacent to the central bore.