Brushless Motor Stator Core Circularity and Fixing Force
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Solution Overview
Problem
The existing brushless motor configurations face issues with the deterioration of stator core circularity and low axial fixing force due to plastic deformation in the case integration process, leading to inadequate fixing force between the case and stator core.
Innovation Solution
A brushless motor design featuring a stator core with an outer ring-shaped section, teeth, and an inner ring-shaped section, where protruding portions on the outer ring-shaped section are formed to project radially outward and are integrated with the case using plastic deformation portions at even intervals, maintaining the circularity of the inner ring-shaped section and enhancing the fixing force by concentrating stress at specific locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If plastic deformation portions are formed on the outer peripheral portion of the case to integrate the case and stator core, then the fixing force in the circumferential direction is improved, but the circularity of the stator core deteriorates
Solution Approach 1:
The stator core is divided into multiple segments (first through fourth stator cores) arranged circumferentially. Each segment has its own plastic deformation portion formed on the case, distributing the deformation stress and preventing excessive pressure on any single location, thereby maintaining overall circularity while achieving circumferential fixing
Solution Approach 2:
Protruding portions are added to the outer peripheral portion of the stator core at specific locations corresponding to the plastic deformation portions. These protruding portions concentrate the contact area and stress at discrete points, improving fixing force locally without requiring continuous pressure that would deteriorate the overall circularity
2Reliability
If the case is pressed against the stator core to form plastic deformation portions, then the integration between case and stator core is improved, but the axial fixing force remains comparatively low
Solution Approach 1:
The fixing mechanism is extended from a single radial direction to multiple dimensions by combining radial plastic deformation portions with axial protruding portions. The protruding portions extend in the axial direction and engage with corresponding features on the rotor, providing axial fixing force while the plastic deformation portions provide circumferential integration
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 improves the circularity of the stator core and increases the fixing force between the case and stator core, ensuring a tighter fit and improved mechanical stability.
Implementation Method 1
plural plastic deformation portions formed at an outer peripheral portion of the stator case at locations facing towards the protruding portions
Data Source
AI summary
A brushless motor comprising: a rotor; a stator core disposed at a radial direction outside of the rotor, and a stator case. The stator core includes an outer ring shaped section, teeth sections projecting out from the outer ring shaped section toward a radial direction inside, and an inner ring shaped section extending from end portions of the teeth sections. Protruding portions are formed at the outer ring shaped section so as to project toward a radial direction outside and so as to be disposed at even intervals around a circumferential direction of the outer ring shaped section. The stator case is integrated together with the stator core by a plurality of plastic deformation portions formed at an outer peripheral portion of the stator case at locations facing towards the protruding portions, and the plastic deformation portions are disposed at even intervals along a circumferential direction of the stator case.