Stator Assembly Design for Stepper Motor Integration
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Solution Overview
Problem
Current stator assemblies for stepper drive motors in adaptive automobile headlight systems have complex assembly processes, low production efficiency, and high costs due to a large number of parts, complicating automated production and integration.
Innovation Solution
A stator assembly design featuring injection overmolded pole pieces with a Y-shaped connection port, a coil, a pin connector with a ground pin, and a magnetically conductive ring, along with a metallic sleeve replacing traditional bearings, simplifies the assembly and reduces the number of parts, enhancing production efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional stator assembly with multiple separate parts (two pole pieces, two coil frameworks, two stator casings, external connector) is used, then the assembly provides functional completeness, but the number of parts increases, assembling process becomes complicated, and production efficiency decreases
Solution Approach 1:
The patent merges multiple separate components (pole pieces, coil frameworks, stator casings, connectors) into an integrated stator assembly. The pole pieces are combined with coil frameworks to form unified structures, and the stator casings are integrated to enclose all components while providing mounting functions. This consolidation reduces the number of discrete parts from multiple separate components to a unified assembly, directly addressing the contradiction by simplifying the assembling process while maintaining functional completeness.
2Productivity
If multiple separate components are used in the stator assembly, then functional requirements are met, but production costs increase and automated production becomes difficult
Solution Approach 1:
The integration of multiple components into a unified stator assembly directly reduces part count, which simplifies automated production processes. The consolidated structure eliminates the need for multiple handling, positioning, and fastening operations that would be required for separate components, thereby increasing production efficiency and enabling easier automation.
Solution Approach 2:
The stator assembly is designed as a multi-functional integrated unit where the stator casings serve both structural enclosure and mounting functions, the pole pieces are integrated with coil frameworks to combine magnetic and electrical functions, and connectors are built-in rather than external. This multi-functionality reduces the number of specialized parts needed, lowering production complexity and cost while maintaining all required functions.
3Adaptability or versatility
If traditional separate components are used, then assembly flexibility is maintained, but integration level decreases and costs increase
Solution Approach 1:
The patent achieves high integration by merging pole pieces with coil frameworks into unified structures, integrating connectors within the stator assembly rather than using external connectors, and combining stator casings to enclose and structurally support all components. This integration increases the overall system cohesion and reduces the number of interface connections needed, directly addressing the contradiction by提高 integration level while reducing part count.
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 novel stator assembly design significantly reduces the number of parts, simplifies the assembly process, and lowers production costs while maintaining electromagnetic compatibility and efficiency in the stepper drive motor for adaptive headlight systems.
Implementation Method 1
a coil wound around the stator
Implementation Method 2
a magnetically conductive ring, the stator, which is mounted with the coil and the pin connector, being pressed into the magnetically conductive ring
Implementation Method 3
the rotor is pressed into the annular magnet in an interference fit manner
Data Source
AI summary
A stator assembly, having a stator formed by a plurality of pole pieces by means of injection overmolding, a columnar connection portion protruding outward being provided on an edge of one of the pole pieces; a mounting groove located at a side face of the stator; a coil wound around the stator; a pin connector with a ground pin, the pin connector being press-fitted onto the mounting groove in the direction perpendicular to the axial direction of the stator; and a magnetically conductive ring, the stator, which is mounted with the coil and the pin connector, being pressed into the magnetically conductive ring. The stator assembly has the features of having few parts and being convenient to assemble.