Electric Motor Stator Assembly Lug Recess Fixing
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Solution Overview
Problem
Electric motors with stator cores used for structural support and positioning become bulky, heavy, and expensive due to the need for high-tolerance manufacturing and magnetic 'pinch points' caused by mounting features like through-holes and cut-away portions, which reduce efficiency and performance.
Innovation Solution
The stator assembly is fixed to a frame using a bobbin assembly with c-shaped stator cores, eliminating the need for intrusive mounting features and allowing for a smaller, lighter, and cheaper motor design, with the bobbin assembly bearing the duty of fixing the stator assembly to the frame, and utilizing an interference fit or adhesive for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the stator core is used for structural support and positioning, then the stator assembly can be fixed to the frame, but the stator core becomes bulky, heavy and expensive
Solution Approach 1:
The invention separates the structural support function from the magnetic function by introducing a dedicated fixing structure (lug and recess) that is distinct from the stator core. The stator core is divided into a magnetic core portion and a yoke portion, where only the yoke portion provides structural support for mounting, while the magnetic core portion is optimized purely for magnetic performance without structural constraints.
Solution Approach 2:
The invention extracts the structural support function from the stator core and assigns it to a separate fixing structure (lug on the yoke portion). This allows the stator core to be redesigned without structural constraints, eliminating the need for bulky designs and reducing weight while maintaining the structural support capability through the dedicated fixing features.
2Strength
If mounting features like through-holes and cut-away portions are added to the stator core, then the stator assembly can be fixed to the frame, but magnetic saturation occurs reducing efficiency and performance
Solution Approach 1:
The invention extracts the mounting features from the magnetic core portion and relocates them to the yoke portion. The fixing structure comprises a lug extending from the yoke portion that engages with a recess in the frame, completely avoiding the need for through-holes or cut-away portions in the magnetic core. This preserves the magnetic path integrity and eliminates magnetic saturation losses.
Solution Approach 2:
The yoke portion acts as an intermediary between the magnetic core and the frame. It provides the structural interface for mounting (lug and recess engagement) while the magnetic core remains intact without any mounting features. The adhesive applied to the lug further mediates the connection, distributing mechanical stresses away from the magnetic core.
3Manufacturing precision
If the stator core is made robust and high-tolerance for structural role, then positioning accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The invention segments the positioning function between the yoke portion's fixing structure (lug and recess) and the magnetic core. The lug-recess interface provides the structural positioning with appropriate tolerances, while the magnetic core can be manufactured with standard tolerances without requiring high-precision structural features, reducing manufacturing complexity and cost.
Solution Approach 2:
The invention extracts the high-tolerance structural positioning requirements from the magnetic core and assigns them to the yoke portion's fixing structure. The lug and recess can be manufactured with standard tolerances using conventional processes, eliminating the need for expensive high-precision machining of the magnetic core while maintaining accurate positioning.
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 results in a more efficient and cost-effective electric motor with reduced magnetic saturation, improved performance, and easier manufacturing, while maintaining precise relative positioning of the stator and rotor assemblies.
Implementation Method 1
The lug may be fixed inside the recess of the bobbin assembly by one or a combination of an interference fit and adhesive.
Implementation Method 2
The lug may be fixed inside the recess of the bobbin assembly by one or a combination of an interference fit and adhesive.
Data Source
AI summary
An electric motor comprising: a frame; and a stator assembly; the stator assembly including a bobbin assembly and at least one c-shaped stator core. The frame comprises at least one lug, the bobbin assembly includes at least one recess, and the stator assembly is fixed to the frame by fixing the lug inside the recess of the bobbin assembly.