Split-Core Stator with Insulator-Integrated Hall Sensor Mounting
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Solution Overview
Problem
The existing stator configurations for motors with Hall effect sensors require additional components to attach the sensor, increasing manufacturing costs and complexity.
Innovation Solution
A stator design featuring split cores with insulators that hold the Hall effect sensor in place, eliminating the need for specific holding members and allowing for a simpler configuration and precise positioning of the sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bridges are provided to fix the Hall effect sensor, then the sensor can be securely attached, but the number of components increases and manufacturing cost increases
Solution Approach 1:
The patent combines the sensor holding function with the existing stator core structure by forming holding parts directly on the insulators that surround the teeth. This eliminates the need for separate bridge components while maintaining secure sensor attachment. The insulators serve dual purposes: electrical insulation and mechanical sensor support.
Solution Approach 2:
The insulators are designed to perform multiple functions: providing electrical insulation between the teeth and serving as mounting structures for the Hall effect sensor through integrated holding parts. This multi-functionality reduces the overall component count while maintaining all necessary functions.
2Reliability
If bridges are provided to fix the Hall effect sensor, then the sensor can be securely attached, but manufacturing cost increases
Solution Approach 1:
The patent merges the sensor mounting function into the existing insulator components, eliminating the need for separate bridge parts. This reduction in component count directly lowers manufacturing costs while maintaining secure sensor attachment through the integrated holding parts formed on the insulators.
3Measurement precision
If the Hall effect sensor is positioned close to the permanent magnet, then magnetic flux detection is improved, but the sensor attachment structure becomes more complex
Solution Approach 1:
The patent integrates the sensor holding function directly into the insulators that are already positioned close to the permanent magnet for optimal detection. The holding parts are formed on these insulators, allowing the sensor to be securely mounted in the optimal position without requiring additional complex attachment 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
This design simplifies the attachment of the Hall effect sensor, reduces manufacturing costs, and enhances the accuracy of magnetic flux detection, thereby improving motor performance.
Implementation Method 1
a Hall effect sensor for detecting a rotation angle of a rotor is attached to a stator. The Hall effect sensor detects magnetic flux caused by a permanent magnet.
Data Source
AI summary
A stator includes a first split core having a first yoke part extending in a circumferential direction about an axis line and a first tooth extending from the first yoke part toward the axis line, a second split core having a second yoke part extending in the circumferential direction and a second tooth extending from the second yoke part toward the axis line, a first insulator arranged to surround the first tooth and having a first holding part located between a tip end part of the first tooth and a tip end part of the second tooth, a second insulator arranged to surround the second tooth and having a second holding part located between the tip end part of the first tooth and the tip end part of the second tooth, and a Hall effect sensor held by the first holding part and the second holding part.