Segmented Stator Bus Bar Assembly for Rotor Bearing Alignment
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Solution Overview
Problem
Existing electric motor stators face challenges in efficiently connecting and supporting rotor assemblies due to complex wiring and bearing systems, leading to potential misalignment and reduced motor performance.
Innovation Solution
The design incorporates a segmented stator assembly with overmolded insulators, bus bar assemblies, and printed circuit board assemblies, featuring interconnected stator segments, molded bodies, and rotor bearings to securely connect and align rotor shafts, ensuring efficient electrical and mechanical support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex wiring and bearing system is used to connect rotor assemblies, then electrical connections can be established, but misalignment and reduced motor performance occur
Solution Approach 1:
The patent combines the bearing support function and electrical connection function into a single integrated stator segment structure. The bearing is directly mounted on the stator segment core, and the wire leads from coil windings are directly connected to the bearing assembly, eliminating separate wiring systems and reducing misalignment issues between previously separate components.
Solution Approach 2:
The stator segment structure serves multiple functions simultaneously: it provides magnetic core structure for electromagnetic induction, supports the rotor bearing for mechanical rotation, and establishes electrical connections through integrated wire leads. This multi-functional design reduces the number of separate systems needed and improves overall alignment.
2Manufacturing precision
If segmented stator assembly with integrated bearing and wiring is used, then alignment and support are improved, but manufacturing complexity increases
Solution Approach 1:
The stator is divided into multiple modular stator segments that can be manufactured separately and then assembled. Each segment is a complete functional unit with integrated bearing and electrical connections, allowing for precise manufacturing of individual segments that maintain alignment when assembled together.
Solution Approach 2:
The bearing and electrical wire leads are pre-integrated into the stator segment structure during manufacturing, before final assembly. This preliminary integration ensures proper alignment is built-in during segment production, and the segments can be quickly assembled without complex field alignment procedures.
3Productivity
If traditional stator design is used, then manufacturing is simpler, but motor performance and efficiency are reduced
Solution Approach 1:
The patent merges previously separate components (stator core, bearing, and electrical wiring) into an integrated stator segment assembly. This integration eliminates misalignment between separate components, improving electromagnetic efficiency and motor performance while the modular segmented design keeps manufacturing manageable.
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 alignment and support of rotor assemblies, improving motor performance by ensuring reliable electrical connections and mechanical stability, thereby increasing efficiency and durability.
Implementation Method 1
Each stator segment includes a core, an insulator at least partially covering the core, and a coil winding
Data Source
AI summary
A power tool includes a housing and an electric motor. The electric motor includes a rotor assembly including a rotor shaft and a stator assembly including a plurality of stator segments. Each stator segment includes a core, an insulator at least partially covering the core, and a coil winding. The insulator includes a mounting portion. The electric motor also includes a printed circuit board assembly configured to direct electric current to each coil winding, and a bus bar assembly attached to at least one of the mounting portions and configured to electrically connect the coil windings to the printed circuit board assembly. The bus bar assembly includes a molded body and a plurality of conductors. The bus bar assembly defines a bearing pocket. The electric motor further includes rotor bearing that is received into the bearing pocket and that supports the rotor shaft for rotation relative to the stator assembly.