Single-Phase Brushless Motor Volume Reduction via Segmented Stator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing single-phase brushless motors have a larger volume due to reduced effective space in stator coils, making them unsuitable for miniaturization requirements.
Innovation Solution
A mounting structure comprising a stator assembly and a rotor assembly is optimized, with the stator coils wound around a coil bobbin, and magnetic yokes inserted into a through hole, forming an inner hole, and an uneven air gap between the stator and rotor assemblies, which reduces iron and copper losses and increases efficiency, allowing for a smaller motor volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stator coils are wound around stator teeth, then the motor can be constructed with traditional winding method, but the effective space of windings is reduced leading to larger motor volume
Solution Approach 1:
The stator core is divided into two separate core blocks with U-shaped and inverted U-shaped structures. These segmented core blocks are assembled together to form the complete stator, allowing coils to be wound on the coil bobbin before assembly. This segmentation enables better space utilization and reduces the overall motor volume while maintaining traditional winding advantages.
Solution Approach 2:
The coil bobbin is inserted into the coil-receiving recess of the core blocks, and the core blocks are then assembled together to form the complete stator assembly. This nested structure allows efficient use of space and reduces motor volume while maintaining the effectiveness of the winding arrangement.
2Device complexity
If traditional stator structure is used, then the motor structure is simple, but the motor volume is larger and cannot meet miniaturization requirements
Solution Approach 1:
The stator is segmented into two core blocks that can be assembled together. This segmentation allows for more compact arrangement of magnetic paths and windings, reducing the overall motor volume while maintaining structural simplicity through modular assembly.
Solution Approach 2:
The invention utilizes a three-dimensional assembly approach where the two core blocks are positioned at opposite ends of the coil bobbin and connected through magnetic yokes. This spatial arrangement optimizes the use of available space and achieves miniaturization while keeping the structure relatively simple.
3Loss of energy
If efficiency is improved through optimized electromagnetic circuit, then power consumption decreases, but the structural complexity increases
Solution Approach 1:
The invention introduces localized features such as ventilation slots in the tooth portions and an uneven air gap between stator and rotor assemblies. These local modifications optimize the electromagnetic circuit and improve efficiency by reducing losses, while the overall structure remains relatively simple through targeted rather than comprehensive redesign.
Solution Approach 2:
The invention optimizes the air gap configuration between stator and rotor assemblies by creating an uneven air gap rather than a uniform one. This parameter change improves the electromagnetic circuit efficiency and reduces losses without requiring complex additional structures.
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 optimized structure decreases the motor's volume while maintaining or improving efficiency, meeting the miniaturization requirements of single-phase brushless motors.
Implementation Method 1
Motors, which are devices that convert electric energy into mechanical energy under the principle of electromagnetic induction
Implementation Method 2
magnets having two poles... the rotor assembly comprises an integral bearing, one end of the integral bearing being connected to an impeller, and the other end being mounted around the magnets
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to the technical field of brushless motor. Disclosed herein is a single phase brushless high-speed motor, comprising: an outer housing, a stator assembly, and a rotor assembly; the stator assembly including a coil bobbin, stator coils and a stator core; a coil-receiving recess being arranged on the outer surface of the coil bobbin and a through hole being defined in the central part of the coil bobbin for connection; the stator core including two W-shaped core blocks, which comprise tooth portions, two opposite ends of the tooth portions being provided with a first magnetic yoke and a second magnetic yoke; the tooth portions of the stator core being engaged with each other to form an inner hole of the stator; the first magnetic yoke and second magnetic yoke of the stator core being inserted into the through hole of the coil bobbin respectively from both sides, thereby forming the stator assembly; the rotor assembly comprising an integral bearing, one end of the integral bearing being connected to an impeller, and the other end being mounted around magnets, which form magnetic body having two poles; wherein a Printed Circuit Board (PCB) assembly is mounted on the coil bobbin. The volume of the single-phase brushless motor is decreased and the requirements for the miniaturization of single-phase brushless motors are satisfied by arranging a mounting structure comprising a stator assembly and a rotor assembly.