Stator Press-Fit Assembly for Simpler Electric Machine Mounting
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Solution Overview
Problem
Existing electric machines require complex and costly screw connections for positioning and fixing the stator to the carrier, which complicates manufacturing and increases cycle time.
Innovation Solution
The stator is positioned and fixed to the carrier using a press fit between stator pins and the carrier, eliminating the need for screw connections and allowing for direct thermal and electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections are used to fix the stator to the carrier, then the stator is securely positioned and fixed, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The invention extracts and eliminates the screw connections from the assembly process. Instead of using separate fastening elements, the stator is directly pressed onto the carrier with its own weight providing the fixing force, thereby removing the complexity of screw connections while maintaining secure positioning.
Solution Approach 2:
The stator serves itself by using its own weight to provide the necessary fixing force. The heavy stator naturally presses against the carrier, creating friction and mechanical interlocking without requiring external fastening elements, thus simplifying the manufacturing process while ensuring reliable positioning.
2Reliability
If screw connections are used to fix the stator to the carrier, then the stator is securely attached, but the manufacturing cycle time increases
Solution Approach 1:
The invention removes the time-consuming screw connection step from the manufacturing process. By using the stator's own weight for attachment, the assembly process is reduced to a simple pressing operation, significantly decreasing manufacturing cycle time while maintaining secure attachment.
Solution Approach 2:
The stator automatically attaches to the carrier through its own weight during the pressing operation, eliminating the need for separate fastening operations. This self-attaching mechanism dramatically reduces the manufacturing cycle time while ensuring reliable attachment.
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 method provides a reliable, stable, and cost-effective solution for positioning and fixing the stator, simplifying manufacturing, reducing cycle time, and enhancing cooling and electromagnetic interference compensation.
Implementation Method 1
The press fit between the respective pin and the stator further leads to a direct contact between the stator and the respective pin. This leads to a heat transfer from the stator to the respective pin and thereby to the carrier.
Implementation Method 2
The stator is axially pressed onto the at least one pin so that the stator is attached to the respective pin by means of a press fit, wherein the at least one press fit positions the stator relative to the carrier and fixes the stator to the carrier.
Data Source
AI summary
An electric machine, e.g., an electric motor for a fan, and a method of manufacturing are disclosed. The electric machine includes a rotor that rotates in operation about an axis of rotation that is parallel to a motor axial direction, a stator extending in a motor circumferential direction, and a carrier extending radially with respect to the motor axial direction. The stator is attached to the carrier. At least one pin is arranged radially offset to the axis of rotation is fixed to the carrier and projects axially from the carrier. The stator is axially pressed onto the at least one pin so that the stator is attached to the at least one pin via a press fit and so that the press fit positions the stator relative to the carrier and fixes the stator to the carrier.