Brushless DC Motor Stator Shape Maintenance Without Sleeve
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional brushless DC motor stators require a sleeve for winding and maintaining shape, which is unnecessary and can lead to terminal damage during assembly, making manufacturing complex and assembly challenging.
Innovation Solution
A stator design featuring a cylindrical member formed by metal wires with terminals and a positioning member that maintains the shape and includes engaging members for secure fixation, allowing direct assembly and electrical connection without the need for a separate sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a sleeve is used to wind and maintain the shape of metal wires in a conventional stator, then the stator can be formed with a predetermined cylindrical shape, but the structure becomes more complex and the sleeve serves no other purpose than winding and shape maintenance
Solution Approach 1:
The patent combines the positioning member with the metal wires themselves by making the positioning member an integral part of the cylindrical structure. The metal wires form both the cylindrical member and incorporate positioning functionality, eliminating the need for a separate sleeve. This merging of functions reduces structural complexity while maintaining the predetermined cylindrical shape.
2Ease of manufacture
If a separate sleeve is used for winding metal wires, then the winding process can be facilitated, but the assembly process becomes more challenging and terminals are vulnerable to damage during assembly
Solution Approach 1:
The positioning member is pre-formed and integrated into the cylindrical structure before the winding process. This preliminary positioning structure guides the metal wires during winding and secures the terminals in place before assembly begins, preventing terminal damage during subsequent assembly operations. The positioning member performs the protective function in advance, before potential damage could occur.
3Shape
If a conventional stator with a separate sleeve is used, then the stator can maintain its shape, but the assembly process requires additional steps and the stator cannot be directly fixed in a predetermined location
Solution Approach 1:
The positioning member serves multiple functions simultaneously: it maintains the cylindrical shape of the stator, guides the winding process, secures the terminals, and provides direct fixation capability to the predetermined location. This multi-functionality eliminates the need for separate assembly steps and allows the stator to be directly fixed in its final position without requiring a separate sleeve for shape maintenance.
Data Source
AI summary
A stator for a brushless DC motor includes a cylindrical member and a positioning member. The cylindrical member is formed by a plurality of metal wires. Each metal wire includes two ends each forming a terminal. The cylindrical member includes first and second ends separated along a longitudinal axis. The positioning member includes an annular body received in the first end of the cylindrical member and separated from the second end of the cylindrical member along the longitudinal axis. The positioning member maintains a shape of the cylindrical member. The stator can be mounted in a space defined by a housing and a base engaged with the housing, forming a brushless DC motor. A bearing and a circuit board are mounted in the space. The bearing rotatably supports a shaft. A permanent magnet is mounted to the shaft and aligned with the stator.