Motor Stator Core Support Structure for Minimal Rotor Gap
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Solution Overview
Problem
The gap distance between the stator core of a motor and the permanent magnet of the rotor is increased due to the thickness of the support structure for fixing the stator core, leading to degraded motor performance.
Innovation Solution
A stator core structure with a plate portion and protrusions is coupled to a support structure, minimizing the gap distance by using a non-magnetic engineered plastic material for the support structure and incorporating a cooling mechanism with a housing and cooling oil inlet/outlet to enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a support structure with sufficient thickness is used to fix the stator core, then the structural strength and stability are improved, but the gap distance between the stator core and rotor increases, degrading motor performance
Solution Approach 1:
The support structure is divided into multiple functional zones: a first support portion with greater thickness for structural strength, and a second support portion with reduced thickness for minimizing gap distance. This segmentation allows different regions to serve different purposes - structural support versus performance optimization.
Solution Approach 2:
The support structure exhibits local quality variation where the thickness is non-uniform: thicker at the first support portion for strength, and thinner at the second support portion for performance. This local differentiation resolves the contradiction by optimizing each region for its specific function.
2Productivity
If the support structure thickness is reduced to minimize gap distance, then motor performance is improved, but the structural strength and stability deteriorate
Solution Approach 1:
The support structure is segmented into a first support portion for strength and a second support portion for performance, allowing the structure to simultaneously achieve both structural integrity and minimized gap distance for optimal motor performance.
Solution Approach 2:
The support structure transitions from a uniform two-dimensional cross-section to a three-dimensional variable thickness profile, enabling different regions to provide different functions - structural support in one area and gap minimization in another.
3Ease of manufacture
If a traditional uniform support structure is used, then manufacturing is simpler, but the gap distance cannot be minimized, leading to performance degradation
Solution Approach 1:
The support structure is segmented into different thickness regions that can be manufactured using standard molding techniques, achieving variable geometry without significantly complicating the manufacturing process while optimizing motor performance.
Data Source
AI summary
A stator of a motor has a structure including a plate portion coupled to a support structure for fixing a stator core and protrusions inserted into a bobbin. The support structure for fixing the stator core has a structure into which the protrusions of the stator core are inserted and extend into and on which the plate portion of the stator core is inserted and seated. The plate portion of the stator core is joined to the support structure while being coplanar with the support structure. Accordingly, the distance of a gap between the stator core of the stator and a permanent magnet of a rotor is minimized, thereby improving the performance of the motor.