Flat-Wall Stepper Motor Housing for Compact Coil Assembly
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Solution Overview
Problem
Existing stepper motors have a circular cross-section housing that limits assembly space, hindering product miniaturization.
Innovation Solution
A stepper motor design featuring a rotor assembly with a steel magnet and stator assembly that includes a housing with planar outer walls and hollowed-out portions to accommodate the coil, reducing the motor's size perpendicular to the outer wall and facilitating easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a circular cross-section housing is used, then the structural strength is maintained, but the assembly space size is increased which hinders product miniaturization
Solution Approach 1:
The patent changes the housing cross-section from a symmetric circular shape to an asymmetric shape with at least one flat outer wall surface. This asymmetric design reduces the bounding box dimensions of the motor while the flat surfaces provide stable mounting interfaces, thereby achieving miniaturization without compromising structural integrity or assembly stability
2Volume of moving object
If the housing size is reduced for miniaturization, then the assembly space is reduced, but the coil accommodation space is insufficient
Solution Approach 1:
The patent implements a nested structure where the coil is positioned within the stator assembly, and the stator assembly is nested within the housing. The flat outer wall design allows the coil to be arranged in a compact configuration that fits within the reduced housing dimensions while maintaining adequate winding space, effectively nesting components to maximize space utilization
3Ease of manufacture
If a circular housing is used, then the manufacturing process is simple, but the assembly mating with other parts is difficult
Solution Approach 1:
The patent applies local quality by maintaining a simple overall housing structure for ease of manufacture, while introducing flat outer wall surfaces at specific locations to provide stable mating interfaces for assembly. This localized modification of the housing geometry enhances assembly compatibility without significantly complicating the manufacturing process
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 achieves miniaturization of the stepper motor, enhances assembly ease, and allows for potential improvements in torque performance or increased coil turns, while maintaining structural strength.
Implementation Method 1
a coil sleeved to an outer side of the fixation claw pole
Implementation Method 2
a steel magnet sleeved to an outer side of the rotary shaft
Data Source
AI summary
The present disclosure relates to the technical field of motors and, in particular, to a stepper motor. The stepping motor of the embodiments of the present disclosure includes a rotor assembly and a stator assembly. The stator assembly includes a fixation claw pole, a coil, and a housing. The housing includes a plurality of housing walls sequentially connected in a circumferential direction of the coil. The plurality of housing walls include at least one first housing wall. Each first housing wall has a planar outer wall and is formed with a hollowed out portion configured to avoid the coil.