PMDC Motor Housing with Flat Mounting Surface
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Solution Overview
Problem
Existing miniature permanent magnet direct current (PMDC) motors with curved side portions offer higher power density and lower noise but are difficult to install due to their complex housing design.
Innovation Solution
A PMDC motor design featuring a stator with n alternately distributed side and connecting portions, where each side portion is a convex curved line, along with an end cap having a flat mounting surface for easier installation, and additional components like brushes, thermistors, chokes, and a cup-shaped cover for enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the housing has curved side portions to increase power density and reduce noise, then the motor performance is improved, but the installation difficulty increases
Solution Approach 1:
The housing is segmented into n side portions and n connecting portions distributed alternately. Each side portion has a convex curved cross section for performance optimization, while each connecting portion provides a flat outer surface for simplified installation and mounting. This segmentation allows different parts of the housing to serve different functions.
Solution Approach 2:
Different portions of the housing have different geometric properties: side portions feature convex curved cross sections to optimize motor performance, reduce noise, and increase power density, while connecting portions have flat outer surfaces specifically designed for easy installation and mounting operations. Each local region is optimized for its specific function.
2Power
If the housing has curved side portions to increase power density, then the motor performance is improved, but the manufacturing complexity increases
Solution Approach 1:
The housing is divided into side portions requiring curved geometry for performance and connecting portions requiring flat geometry for manufacturing simplicity. This segmentation allows each portion to be manufactured using appropriate methods without compromising the other requirements.
Solution Approach 2:
The housing exhibits asymmetric geometry where side portions are convex curved to optimize performance characteristics, while connecting portions are flat to simplify manufacturing and installation. This asymmetric design allows optimization of different regions for different priorities.
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
The design achieves high power density and low noise while simplifying the installation process and providing improved stability and functionality through the flat mounting surface and additional components.
Implementation Method 1
a permanent magnet motor comprising a stator and a rotor rotatably mounted to the stator, the stator comprising a housing having n side portions and n connecting portions distributed alternately
Implementation Method 2
permanent magnets fixed to an inner surface of the housing
Implementation Method 3
the end cap supports a first brush and a second brush for sliding contact with the commutator
Implementation Method 4
a thermistor electrically connected in series between the first brush and the first terminal for over current protection
Data Source
AI summary
A permanent magnet motor has a stator and a rotor rotatably mounted to the stator. The stator has a housing with n side portions and n connecting portions distributed alternately, wherein n is a integer equal to or greater than 3. Adjacent side portions are interconnected by one of the connecting portions. The radial cross section of each side portion is a convex curved line which is curved outwardly relative to a straight line passing through the two ends of the convex curve line. Permanent magnets are fixed to an inner surface of the housing. An end cap fixed to one end of the housing, has a bottom and n side walls extending from the bottom. A flat mounting surface is formed at the outer surface of a first one of the side walls.