Electric Motor Stator Segmented Teeth Connection Frames
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Solution Overview
Problem
Electric motors for electric bicycles face challenges in providing high torque with reduced speed of rotation while being compact and minimizing noise, especially due to space constraints and the need for compatibility with pedaling rates.
Innovation Solution
A stator design for electric motors featuring a plurality of teeth with coils wound around them, utilizing separate removable teeth and dual lead frames for electrical connections, configured in star or delta arrangements, and using fractional winding pitches to achieve high torque and reduced size, with electrical insulation and non-conductive walls to manage noise and space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the electric motor is designed to provide high torque with low rotational speed, then the motor can effectively assist pedaling, but the motor size increases making integration difficult
Solution Approach 1:
The stator is divided into separate removable teeth that can be independently positioned and secured. This segmentation allows for optimized magnetic circuit design with reduced air gaps between teeth and coils, improving torque density without increasing overall motor volume. The modular tooth structure enables efficient space utilization in the stator assembly.
Solution Approach 2:
Connection frames are positioned in multiple spatial dimensions - both internally within the stator body and externally on the outer surface. This multi-dimensional arrangement of electrical connections optimizes current path efficiency and reduces resistive losses, enabling higher torque output from a compact motor structure.
2Force
If the electric motor is positioned at the bottom bracket to assist pedaling, then effective assistance is provided, but space constraints prevent integration without compromising other bicycle features
Solution Approach 1:
The separate removable teeth are nested within the stator body structure, with each tooth fitting into precisely formed recesses. This nested arrangement maximizes the utilization of available space in the bottom bracket area, allowing the motor to deliver high torque assistance while maintaining a compact footprint that does not compromise other bicycle features.
3Volume of moving object
If the motor is designed for compact dimensions, then integration is easier, but noise production increases
Solution Approach 1:
The separate teeth are pre-positioned and secured in their final locations within the stator body before coil installation. This preliminary positioning ensures optimal alignment and minimizes air gaps, reducing magnetic noise. The connection frames are also pre-configured with proper electrical connections, eliminating assembly-related noise sources in the compact motor design.
4Ease of manufacture
If separate removable teeth are used in the stator, then manufacturing and assembly are simplified, but electrical connection complexity increases
Solution Approach 1:
Multiple electrical connection functions are merged into integrated connection frames that are positioned both internally and externally on the stator body. These frames simultaneously provide electrical connectivity for multiple coils and serve as structural mounting elements, simplifying the overall assembly process despite the presence of separate removable teeth. The multi-dimensional connection frame arrangement consolidates electrical pathways, reducing the complexity of wire routing and connections.
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 design enables the production of high-torque electric motors with reduced size and noise, enhancing compatibility with pedaling rates and allowing for easier integration into electric bicycles, while maintaining efficient electrical connections and compact dimensions.
Implementation Method 1
a stator body comprising a plurality of teeth extending between an outer and an inner portion of the stator body, and a plurality of coils configured to be wound respectively around the plurality of teeth
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a stator (3) for an electric motor (1) comprising: - a stator body (31) comprising a plurality of teeth (35) extending between an external part (31a) and an internal part (31b) of the stator body (31), - a plurality of coils (33) configured to be wound respectively around the plurality of teeth (35) between the external part (31a) and the internal part (31b) of the stator body (31), characterized in that the stator (3) also comprises: - at least one first connection frame (7) disposed on the internal part (31b) of the stator body (31) and configured to ensure electrical connections between the coils (33).