Resin Separation Preventing Member for Brushless Motor Disassembly
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Solution Overview
Problem
Conventional brushless motors face difficulties in disassembly and repair due to the complexity of the separation preventing member's operation from outside the motor, and the challenge of maintaining elasticity and accuracy in its installation, especially in compact and miniaturized designs, leading to reduced joint strength and reliability.
Innovation Solution
The brushless motor incorporates a resin-formed separation preventing member with a latching mechanism that allows easy disassembly and adjustment, featuring a latching protrusion and penetration section for secure attachment, reducing the need for complex metal processing and enhancing assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal cutting and shaving process is used to create the bearing housing with an engaging section, then the separation preventing member can be securely engaged, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the material parameter from metal to resin and the manufacturing process parameter from cutting/shaving to molding. The engaging section is formed directly during resin molding of the bearing housing, eliminating the need for subsequent metal cutting operations while maintaining the structural integrity and engagement functionality.
Solution Approach 2:
The patent replaces the mechanical cutting and shaving process with a molding process. The engaging section is created through resin formation that directly shapes the bearing housing, substituting complex mechanical machining operations with a single-step molding operation that reduces manufacturing complexity.
2Volume of moving object
If the separation preventing member is installed in a narrow space between rotor and stator core, then the motor can be compact, but it becomes difficult to appropriately set the elasticity and maintain bending angle accuracy
Solution Approach 1:
The patent changes the material parameter from metal to resin, which fundamentally alters the elasticity characteristics. Resin provides appropriate flexibility for the narrow space installation while being formable to precise bending angles during the molding process, thereby maintaining manufacturing precision despite the compact dimensions.
Solution Approach 2:
The patent applies preliminary action by pre-forming the engaging section with the exact bending angle during the resin molding process. The separation preventing member is manufactured with its final shape and elasticity characteristics built-in, eliminating the need for subsequent adjustment operations that would be difficult to perform in the narrow installed space.
3Ease of manufacture
If press processing with bending is used to create the separation preventing member, then it can be made from low-cost material, but it becomes difficult to maintain the bending angle with high accuracy
Solution Approach 1:
The patent replaces the mechanical press processing and bending operations with a resin molding process. The engaging section is formed directly in the desired shape during molding, eliminating multiple bending operations and the associated precision losses, while maintaining low material costs through the use of resin.
Solution Approach 2:
The patent changes the manufacturing process parameter from press bending to resin molding. This parameter change enables high precision bending angle control because the resin can be formed to exact specifications during molding, unlike metal which requires multiple bending operations that accumulate dimensional errors.
4Volume of moving object
If the separation preventing member is difficult to operate from outside the motor, then the structure can be compact, but disassembly and repair become difficult
Solution Approach 1:
The patent applies segmentation by designing the engaging section as a separable feature. The bearing housing with its molded engaging section can be detached from the rotor, allowing the separation preventing member to be removed and replaced without disassembling the entire motor, thus maintaining compactness while enabling easy repair.
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 design facilitates easy disassembly and adjustment of the separation preventing member, improves joint strength, and ensures reliable attachment, even in compact designs, by using a resin-formed separation preventing member with a latching mechanism, thereby enhancing the motor's operational reliability and supporting rigidity.
Implementation Method 1
the separation preventing member has elasticity. In assembling the brushless motor, as the shaft 22 is inserted into the bearing 23, the tip of the separation preventing member 25 makes contact with the engaging section 26, and as the shaft 22 is further inserted, it expands in the outer diameter direction of the engaging section 26 by the elasticity of the separation preventing member 25
Data Source
AI summary
In a separation preventing mechanism used in a brushless motor, an insertion section is formed into a separation preventing member (5) using resin, which has a form difficult to shape with a metal pressed part, and to which a latching member (4) can be inserted by combining rotation and shaft-direction insertion, making it easy to disassemble it after assembly and size adjustment.