Separated C-Shaped Stator Iron Core for Brushless Motor Winding
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Solution Overview
Problem
Conventional vacuum cleaner motors, particularly brush motors, have large volumes, low performance, and limited portability due to their integral iron core structure, which complicates wire winding and can damage enameled coatings, hindering high-speed operation and efficiency.
Innovation Solution
A stator structure with a separated C-shaped left and right iron core design allows for independent wire winding and fixation, forming a horse-shoe shaped stator with chamfered and rounded pole shoes, simplifying the winding process and improving production efficiency while avoiding coating damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an integral iron core structure is used, then the structural strength is improved, but the wire winding process becomes complicated and the enameled coating is likely to be damaged
Solution Approach 1:
The iron core is divided into two separate C-shaped halves instead of using an integral structure. This segmentation allows wire winding to be performed independently on each half before assembly, avoiding the complexity and coating damage risks associated with winding on a complete integral core. The two C-shaped halves are then connected through fixing components to form the complete stator structure.
2Power
If the iron core volume is reduced to meet brushless motor requirements, then the motor performance is improved, but the wire winding process becomes more difficult
Solution Approach 1:
By segmenting the iron core into two C-shaped halves, the patent enables wire winding to be performed on smaller, more manageable sections. This segmentation makes the winding process easier even when the overall iron core volume is reduced for high-performance brushless motor applications.
3Device complexity
If a conventional integral iron core is used, then the manufacturing process is standardized, but the production efficiency is reduced due to complicated winding
Solution Approach 1:
The iron core is segmented into two C-shaped halves that can be independently manufactured and wound. This allows parallel processing of multiple components, significantly improving production efficiency while maintaining standardized manufacturing processes for each half.
Solution Approach 2:
The wire winding operation is performed preliminarily on each C-shaped half before the final assembly. This preliminary action on separated components is more efficient than winding on the complete assembled structure, as it allows better access and easier manipulation of the wire.
4Volume of moving object
If the iron core has a small volume for brushless motor requirements, then the motor becomes portable and efficient, but the wire winding process is more difficult
Solution Approach 1:
Segmenting the compact iron core into two C-shaped halves makes the wire winding process feasible despite the small overall volume. Each half provides sufficient space for wire winding while maintaining the compact size required for portable brushless motors.
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 solution enables high-speed, high-performance, portable, and energy-efficient brushless vacuum cleaner motors with improved production efficiency and reduced risk of enameled coating damage, ensuring accurate and stable connections between iron cores.
Implementation Method 1
a coil winding (5) is wound around each of the left iron core (1) and the right iron core (2)
Data Source
Figure 1~2
AI summary
A stator structure of a brushless dust collector motor. The stator structure is a separate-type structure, and comprises a left iron core and a right iron core that are detachably connected. The upper end of the left iron core and the upper end of the right iron core extend to form pole shoes, the front edges of the pole shoes are deviated leftwards with the centers of the inner circles of the pole shoes as the benchmarks, chamfers of 30 to 60 degrees are formed, and the rear edges of the pole shoes are provided with fillets. Pole shoe deflection angles need to be arranged according to the structure of the stator iron cores, and the use requirement for the rotating speed of a brushless motor is met. Because the stator iron cores are designed into the separate-type structure, winding processing can be respectively conducted on the left iron core and the right iron core, and afterwards the two iron cores are fixed, so the stator winding process is simplified, the production efficiency is improved, and a paint layer is prevented from being damaged. The left iron core and the right iron core can be connected and fixed by adopting an embedding mode, so the accuracy of the connecting position of the two iron cores is effectively ensured, and the operation stability and reliability of the motor are improved. The stator structure is applicable in high-speed brushless motors and is advantageous in having a high rotating speed, high performance and a small size, and being convenient to carry and energy-saving and the like.