Split-Core Motor Housing Grooves for Lower Friction Torque
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Solution Overview
Problem
Motors face challenges in reducing friction torque caused by magnetic flux leakage to the housing from the stator and ensuring assembly stability, particularly due to the magnetic interaction between the stator and housing.
Innovation Solution
The motor design incorporates a stator formed by coupling split cores with tooth and yoke parts, and a housing with inner and outer grooves to reduce the contact area between the stator and housing, minimizing magnetic flux leakage and maintaining assembly stability without increasing the assembly gap or using non-magnetic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the stator and housing have direct contact to ensure assembly stability, then assembly stability is improved, but magnetic flux leakage increases causing higher friction torque
Solution Approach 1:
The housing inner surface is segmented into multiple grooves that divide the contact area between stator and housing. These grooves create discrete contact points rather than continuous contact, allowing magnetic flux to be channeled through specific paths while maintaining structural stability. The segmentation reduces the overall contact area and prevents widespread magnetic flux leakage.
Solution Approach 2:
The grooves act as intermediary structures between the stator and housing, modifying the interaction between these components. By introducing these intermediate features, the patent creates controlled magnetic flux paths through the grooves while reducing direct contact area, thereby mediating between the conflicting requirements of stability and flux leakage reduction.
2Object-generated harmful factors
If non-magnetic materials are used for the housing to reduce magnetic flux leakage, then friction torque is reduced, but manufacturing cost increases
Solution Approach 1:
The patent converts the potentially harmful effect of magnetic flux leakage into a beneficial controlled path. By designing grooves with specific geometries and orientations, the magnetic flux that would otherwise cause friction torque is redirected through controlled paths in the grooves, transforming a harmful phenomenon into a manageable design feature that works with the magnetic flux rather than against it.
Solution Approach 2:
The patent changes the geometric parameters of the housing structure by introducing grooves with specific dimensions, depths, and patterns. These parameter changes modify the magnetic flux distribution and contact characteristics without changing the material composition, allowing the use of cost-effective magnetic materials while controlling flux leakage through geometric design.
3Object-generated harmful factors
If the contact area between stator and housing is reduced to minimize magnetic flux leakage, then friction torque is reduced, but assembly stability deteriorates
Solution Approach 1:
The contact area is segmented into multiple discrete regions defined by the grooves, creating a pattern of contact points rather than continuous contact. This segmentation reduces the total contact area to minimize magnetic flux leakage while the distributed nature of the contact points maintains assembly stability through multiple support locations.
Solution Approach 2:
The grooves introduce a new dimensional feature to the housing inner surface, creating a three-dimensional profile that controls magnetic flux paths. By utilizing this additional geometric dimension, the patent reduces contact area in the radial direction while maintaining stability through the axial and circumferential positioning of the groove features.
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 effectively reduces friction torque while maintaining assembly stability by minimizing the contact area between the stator and housing, even when using a cost-effective steel housing, without compromising rigidity or increasing manufacturing costs.
Implementation Method 1
The motor has a structure of rotating the rotor by the magnetic force generated as electricity is supplied to the coil of the stator
Implementation Method 2
The magnetic force generated from the coil may leak to the housing, acting as friction torque
Data Source
AI summary
A motor comprises a stator having a plurality of split cores coupled to one another, each split core including a tooth part and a yoke part; and a housing accommodating the stator in the housing. The motor can secure assembly stability while reducing friction torque due to the magnetic flux leaking from the stator to the housing.