Stator Assembly Stiffeners for Motor Vibration and Noise Reduction
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Solution Overview
Problem
Existing electric motor stator assemblies experience deformation and vibration during operation, leading to noise generation, especially when paired with spoked rotor assemblies that exert increased forces.
Innovation Solution
The stator assembly design includes an annular body with a specific thickness ratio to its outer diameter and radially extending stator teeth with stiffeners positioned between the teeth to resist deformation and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the stator assembly uses a conventional design with thinner annular body, then the manufacturing cost and material usage are reduced, but the stator assembly experiences increased deformation and vibration during operation
Solution Approach 1:
The patent applies local quality by positioning stiffeners at specific locations between the stator teeth rather than uniformly thickening the entire annular body. The stiffeners are strategically placed in regions experiencing highest stress and vibration, providing localized reinforcement where needed while maintaining thinner sections elsewhere to reduce overall weight and material usage.
Solution Approach 2:
The patent employs composite construction by combining the annular body material with stiffener material to create a hybrid structure. The stiffeners act as reinforcement elements within the composite assembly, providing enhanced mechanical properties (stiffness and vibration resistance) without requiring the entire stator assembly to be made from heavier, stronger material.
2Ease of manufacture
If the stator assembly uses a conventional design with standard thickness, then the manufacturing simplicity is maintained, but the vibration and noise generation during operation increase
Solution Approach 1:
The patent applies segmentation by dividing the stator assembly into distinct functional components: the annular body and the separate stiffener elements positioned between the teeth. This segmentation allows the stiffeners to be independently optimized for vibration reduction while keeping the manufacturing process relatively simple, as the stiffeners can be added as separate components rather than requiring complex monolithic construction.
3Strength
If the annular body thickness is increased to reduce vibration, then the structural stability is improved, but the ratio of thickness to outer diameter exceeds optimal design parameters
Solution Approach 1:
The patent applies the extraction principle by removing the need for a uniformly thick annular body and instead extracting only the essential reinforcement function into separate stiffener elements positioned between the teeth. This allows the annular body to maintain its thinner, more geometrically simple form while the stiffeners provide the necessary structural reinforcement, achieving high stiffness without excessive thickness or geometric complexity.
Data Source
AI summary
A stator assembly for an electric motor assembly is provided. The stator assembly includes an annular body extending about a central axis. The annular body includes an inner surface and an outer surface. The annular body has a first thickness defined between the inner surface and the outer surface. The stator assembly also includes at least one stator tooth extending radially from the annular body. The at least one stator tooth includes a first tip spaced radially from the annular body. The at least one stator tooth has a second thickness. A ratio of the first thickness to the second thickness is at least about 1.1.