Segmented Elastomer Vibration Dampers for Brushless Motor Stators
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Solution Overview
Problem
Existing brushless motors face challenges in vibration damping performance due to insufficient damping volumes and complex assembly processes, leading to increased costs and manufacturing time, particularly with individually installed vibration dampers that interfere with each other during assembly.
Innovation Solution
A brushless motor design featuring a plurality of vibration dampers made of elastomer material, arranged in a closed loop configuration, which are integrated into the stator and separated upon assembly, along with a centerpiece that supports a rotatable shaft, enhancing damping performance and simplifying the assembly process by reducing component count and interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single annular vibration damper is used with inner peripheral recesses, primary recesses, and secondary recesses, then the structure can engage with the centerpiece and stator, but the damping volume between recesses may be insufficient for effective vibration damping
Solution Approach 1:
The single annular vibration damper is divided into multiple separate vibration dampers (typically three), each with its own damping volume. This segmentation allows each individual damper to have sufficient damping volume while collectively providing comprehensive vibration damping coverage around the stator, resolving the contradiction between structural engagement capability and adequate damping volume.
2Manufacturing precision
If multiple vibration dampers are designed to be installed individually to the stator, then each damper can be precisely positioned, but the dampers interfere with each other during assembly, making simultaneous installation difficult
Solution Approach 1:
Multiple vibration dampers are merged into a single integrated component structure that is molded as one piece. This merged structure allows all vibration dampers to be installed simultaneously to the stator without mutual interference, while maintaining precise positioning through the integrated design. The merging resolves the contradiction between precise individual positioning and ease of simultaneous assembly.
3Manufacturing precision
If vibration dampers are installed individually, then each damper can be precisely positioned, but the number of components increases, lengthening stock time and increasing costs
Solution Approach 1:
Multiple separate vibration damper components are merged into a single integrated vibration damper assembly. This reduces the total number of components from multiple individual dampers to one unified structure, thereby reducing stock time and assembly complexity while maintaining precise positioning capability through the integrated design.
4Reliability
If the engaging portions of the vibration damper are forcefully engaged to corresponding protrusions, then the vibration damper can be installed, but the installation process becomes difficult and time-consuming
Solution Approach 1:
The vibration dampers are pre-positioned and precisely oriented within the integrated structure before installation to the stator. This preliminary arrangement ensures that the engaging portions are already aligned with the corresponding protrusions, eliminating the need for forceful engagement during installation and making the process easier and faster while maintaining reliable engagement.
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 improves vibration damping performance by increasing damping volume and simplifies assembly, reducing manufacturing time and costs by allowing simultaneous installation of multiple vibration dampers and automatic assembly techniques.
Implementation Method 1
Each of the plurality of vibration dampers is made of an elastomer material
Implementation Method 2
improves vibration damping performance by increasing damping volume
Data Source
AI summary
Each of vibration dampers is separated from each circumferentially adjacent one of the vibration dampers upon cutting of each of a plurality of connectors, which is initially integrally formed with the vibration dampers to circumferentially join between corresponding circumferentially adjacent two of the vibration dampers to form a single closed loop body. At least a part of each of first and second circumferential end portions of each vibration damper is engaged with a corresponding one of outer protrusions of a centerpiece in a circumferential direction of a stator. A primary recess is radially inwardly recessed at an outer peripheral portion of the vibration damper and is engaged with a corresponding one of primary protrusions of the stator in the circumferential direction of the stator.