Description:TECHNICAL FIELD
[001] The present subject matter relates to a motor assembly, more particularly, a configuration of stator and rotor disposed in the motor assembly.
BACKGROUND
[002] In general, a motor assembly is of two types, a radial motor, and an axial 5 motor. The above classification of motor assembly is determined on the basis of orientation and configuration of a central axis of the motor assembly, and the configuration of one or more stators and one or more rotors of the motor assembly.
[003] In general, the radial motor comprising a stator being disposed concentrically and coaxially along the central axis of the motor assembly. The stator 10 is concentrically disposed on a motor shaft and a rotor is disposed concentrically on the motor shaft. The rotor is disposed concentrically to the stator and the rotor is configured to surround the stator. The rotor is configured to have a plurality of magnets, and the plurality of magnets is disposed at a predetermined air gap from the stator. 15
[004] In the above configuration, the stator and the rotor is centrally disposed, and the stator remains in a stationary position during the motion of the motor assembly due to cancellation of the centripetal and centrifugal force from the stator and the rotor respectively.
[005] However, the construction of stator and rotor in the radial motor becomes 20 bulky and heavier with increasing power requirements of the motor assembly. Further, the high volume of the radial motor reduces the power density of the motor assembly and hence multiple radial motors are required to meet the required power requirements. This in turn increases the overall part count and weight of the motor assembly. 25
[006] In general, the axial motor is constructed by aligning the stator and the motor along the motor shaft of the motor assembly, with a predetermined air gap provided between the stator and the rotor. The rotor and the stator are not concentric to each other and is separated by the predetermined air gap. The axial motors are configured to have a plurality of combination of rotor and stator based on the power 30 requirement and the required volume density of the motor assembly.
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[007] In the above construction of the axial motors, the various configurations of the stator and the rotor includes one stator and two rotor motor assembly, two rotor and one stator motor assembly, and one stator and one rotor motor assembly. In general, it is relatively simpler to maintain air gap between one rotor and one stator, however the maintenance of air gap between a plurality of rotors and stators is 5 difficult due to misalignment during assembly of the motor assembly. The misalignment between the plurality of stators and rotors occur due to difficulty in holding and aligning the plurality of stators and rotors one after the other in a assembly line. This leads to difference in predetermined air gap between one set of stator and rotor from the other set of rotor and the same stator. 10
[008] It is essential to maintain uniform air gap between the plurality of rotors and stators in order to maintain high torque output of the motor assembly, and also to minimize the noise and vibrations occurring between the plurality of rotors and the stators which in turn reduces the translational losses of the motor assembly.
[009] Therefore, in order to maintain the adequate air gap between the plurality 15 of rotors and stators in the axial motor, a complex assembly process which uses complex tooling to manufacture each of the plurality of rotors and stators are known. This complex designing and tooling process increases the overall assembly time and also increases the overall complexity in assembly of the axial motor assembly.
[010] Thus, in order to overcome such complex tooling and designing of the 20 motor assembly, additional parts such as an extended arm between the plurality of stators and rotors is provided. However, this additional part increases the overall part count of the motor assembly. Furthermore, during the motion of the motor assembly, the additional part may loosen, and the uniform air gap is not maintained. Moreover, the additional part may also disrupt the overall functioning of the motor assembly. 25
[011] Additionally, the mounting of the additional parts using one or more fasteners not only increases the part count, but also increases the overall frictional and vibrational losses between the additional parts and the plurality of stators and rotors. This in turn increases the overall losses and reduces the power density of the axial motor assembly. 30
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[012] Hence, it is preferred to have an axial motor assembly which reduces the complexity in construction and assembly of the motor assembly without compromising the power density of the motor assembly.
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SUMMARY
[013] The present subject matter provides a motor assembly and a method for assembling the motor assembly. The motor assembly comprises at least one stator and at least one rotor being disposed inside a housing of the motor assembly. The housing of the motor assembly comprising one or more locking provisions to arrest 10 translational and rotational movements of the at least one stator for maintaining uniform air gap between the at least one stator and the at least one rotor and also for enhancing the overall power density of the motor assembly.
[014] As per an aspect of the present invention, a motor assembly comprising at least one stator, at least one rotor, and a housing. The at least one stator and the at 15 least one rotor is provided inside the housing. The at least one stator and the at least one rotor is disposed together for maintaining an air gap between the at least one stator and the at least one rotor. Further, the at least one stator is abutted to the housing for arresting movement of the at least one stator during running condition of the motor. 20
[015] As per an embodiment, the at least one stator is sandwiched between the at least one rotor, and the at least one stator and the at least one rotor is disposed on a motor shaft. Further, the at least one stator is configured to have a plurality of protrusions, and the plurality of protrusions is disposed along one or more peripheral edges of the at least one stator. 25
[016] As per another embodiment, the at least one rotor is configured to have a first diameter D1, and the at least one stator is configured to have a second diameter D2. The second diameter D2 is greater than the first diameter D1.
[017] As per another embodiment, the at least one stator is disposed between the at least one rotor with a predetermined air gap, and the predetermined air gap being 30
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between 0.65 mm to 1mm. Further, the at least one rotor is disposed between the at least one stator with the predetermined air gap ranging between 0.65mm to 1mm. [018] As per another embodiment, the housing is configured to have a plurality of inner protrusions, and the plurality of inner protrusions conforms in shape and profile with the plurality of protrusions of the at least one stator. 5
[019] As per another embodiment, the plurality of inner protrusions are disposed on an outer periphery of one of the housing. Further the plurality of inner protrusions are disposed at a predetermined angle, and also the plurality of protrusions of the at least one stator are disposed at the predetermined angle, wherein the predetermined angle being in a range of 120 to 360 degrees. 10
[020] As per another embodiment, the housing is configured to envelop the at least one stator and the at least one rotor. Furthermore, the plurality of inner protrusions are provided at a clearance height (H1), wherein the clearance height (H1) being between 150-300 microns. The plurality of inner protrusions comprises a stopper. The stopper is disposed at one end of the plurality of inner protrusions and 15 the stopper is configured to have the clearance height H1.
[021] As per another embodiment, each of the plurality of protrusions of the at least one stator is configured to have a groove, and the groove is disposed at one peripheral end of each of the plurality of protrusions of the at least one stator. Further each of the plurality of protrusions is configured to be crescent shaped. 20
[022] As per another embodiment, each of the plurality of inner protrusions of the housing is configured to have a depression, and the depression is disposed at the one end of the plurality of inner protrusions of the housing. Further, the depression of the plurality of inner protrusions of the housing is configured to interlock with the groove of each of the plurality of protrusions of the at least one stator. The 25 interlocking between the groove and the depression is configured to lock the at least one stator inside the housing.
[023] As per another embodiment, the plurality of protrusions of the at least one stator is fastened to the plurality of inner protrusions of the housing using one or more fasteners. The one or more fasteners is fastened through one or more first holes 30 and through one or more second holes. The one or more first holes is disposed on
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the plurality of protrusions of the at least one stator and the one or more second holes is disposed on the plurality of inner protrusions of the housing. [024] As per another embodiment, the air gap is equal to a clearance between the inner periphery of the housing and the one or more rotor, wherein the clearance being in range of 0.65 mm to 1mm. 5
[025] As per another aspect of the present invention, a method of assembling a motor assembly comprises the following steps. Firstly, assembling one of at least one rotor in a housing of the motor assembly. Secondly, assembling a motor shaft, and the motor shaft is configured to pass through the one of the at least one rotor. Thirdly, connecting a second rotor of the at least one rotor through the motor shaft 10 and the at least one rotor is enveloped inside the housing. Fourthly, assembling at least one stator on the motor shaft through an outer diameter of the motor shaft. Fifthly, aligning plurality of protrusions of the at least one stator by the housing for mating of the plurality of protrusions with plurality of inner protrusions of the housing. Sixthly, rotating the at least one stator at a predetermined angle and locking 15 the plurality of protrusions of the at least one stator inside the plurality of inner protrusions of the housing. Finally, securing the plurality of protrusions of the at least one stator to the plurality of inner protrusions of the housing through one or more fasteners.
[026] It is to be understood that both the foregoing general description and the 20 following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPT ION OF THE DRAWINGS
[027] The present invention is described with reference to figures. This 25 invention is implementable in two-wheeled, three wheeled and four wheeled vehicles and any other electrical appliances using an axial motor. The same numbers are used throughout the drawings to reference features and components. Further, the inventive features of the invention are outlined in the appended claims.
[028] Figure 1 illustrates an exploded view of a motor assembly, in accordance 30 with an embodiment of the present subject matter.
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[029] Figure 2 illustrates an exploded view of at least one stator and at least one rotor of the motor assembly, in accordance with an embodiment of the present subject matter.
[030] Figure 3 illustrates a cross section view of the motor assembly along a vertical axis, in accordance with an embodiment of the present subject matter, in 5 accordance with an embodiment of the present subject matter.
[031] Figure 4 illustrates a front view of the at least one stator of the motor assembly, in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter.
[032] Figure 5a illustrates a front view of the housing of the motor assembly, in 10 accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter.
[033] Figure 5b illustrates a left perspective view of the housing of the motor assembly, in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter. 15
[034] Figure 6 illustrates a front perspective view of the at least one stator disposed in a housing of the motor assembly, in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter.
[035] Figure 7 illustrates a front view of the at least one stator being abutted 20 inside the housing of the motor assembly, in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION OF THE DRAWINGS 25
[036] Exemplary embodiments are described with reference to the accompanying drawings. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations, and 30 other implementations are possible without departing from the scope of the disclosed
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embodiments. It is intended that the following detailed description be considered as exemplary only, with the true scope being indicated by the following claims. [037] The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter. Various arrangements may be 5 devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[038] The foregoing disclosure is not intended to limit the present disclosure to 10 the precise forms or particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made in form and detail without 15 departing from the scope of the present disclosure. Thus, the present disclosure is limited only by the claims.
[039] Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “third”, “primary”, “secondary”, “main” or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's 20 understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification. 25
[040] Hence it is an object of the present invention to provide a motor assembly with a construction and ease of assembly of at least a rotor and at least a stator for maintaining uniform air gap and also to overcome other related problems known in the art as explained in the background problem.
[041] It is also an object of the present invention to reduce overall part count and 30 eliminate use of multiple fasteners for maintaining the air gap in the motor assembly.
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[042] It is also an object of the present invention to reduce the effect of vibrations and noise arising from the motor assembly due to non-uniform air gap between the at least one stator and the at least one rotor.
[043] It is also an object of the present invention to reduce translational losses and improve efficiency of the motor assembly. 5
[044] It is also an object of the present invention to provide ease of assembly and also reduce overall assembly time of the motor assembly.
[045] It is also an object of the present invention to reduce separate machining and tooling for each of the at least one stator and at least one rotor and thereby simplify the assembly process of the motor assembly. 10
[046] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[047] Figure 1 illustrates an exploded view of a motor assembly (100), in accordance with an embodiment of the present subject matter. A motor assembly (100) is an axial motor assembly is one embodiment. The motor assembly (100) 15 comprises a housing (102a, 102b). The housing (102a, 102b) being split into one or more parts and includes a first part (102a) and a second part (102b) in one embodiment. The first part (102a) and the second part (102b) conform with each other in shape, size, dimensions, and profile. The housing (102a, 102b) includes a central projection (102c) for receiving a motor shaft (110) of the motor assembly 20 (100). The motor shaft (100) is disposed between the housing (102a, 102b) and is sandwiched fixedly between the first part (102a) and the second part (102b) through a first bearing (104a) and a second bearing (104b).
[048] The motor assembly (100) further comprising at least one stator (108) and at least one rotor (106a, 106b). The at least one stator (108) is disposed and 25 sandwiched between the at least one rotor (106a, 106b) in one embodiment. In another embodiment, the at least one rotor (106a, 106b) is sandwiched and disposed between the at least one stator (108). The at least one stator (108) and the at least one rotor (106a, 106b) being disposed on the motor shaft (110) and the at least one stator (108) and the at least one rotor (106a, 106b) is centrally and coaxially disposed 30 on the motor shaft (110). The at least one stator (108) and the at least one rotor (106a,
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106b) is attached to the motor shaft (110) and the housing (102a, 102b) through one or more fasteners (112). This configuration provides a compact packaging of the at least one stator (108) and the at least one rotor (106a, 106b) of the motor assembly (100). [049] The housing (102a, 102b) is also provided to accommodate one or more 5 reduction gears (114a) of the motor assembly (100), and the one or more reduction gears (114a) are attached fixedly to the second part (102b) of the housing (102a, 102b) using one or more bearings and fasteners (114b, 114c, 114d, 114e).
[050] Figure 2 illustrates an exploded view of at least one stator (108) and at least one rotor (106a, 106b) of the motor assembly (100), in accordance with an 10 embodiment of the present subject matter. The housing (102a, 102b) is configured to envelop the sat least one stator (108) and the at least one rotor (106a, 106b). The at least one stator (108) and the at least one rotor (106a, 106b) is composed of plurality of metal laminated sheets being stacked together to provide the requisite power density of the motor assembly (100). The at least one rotor (106a, 106b) is 15 configured to have a first diameter (D1) and the at least one stator (108) is configured to have a second diameter (D2). In one embodiment, the second diameter (D2) being greater than the first diameter (D1).
[051] The at least one rotor (106a, 106b) being configured to include a plurality of magnets (200a, 200b). The plurality of magnets (200a, 200b) is configured to 20 provide a north pole and a south pole for generating magnetic flux for rotation of the motor assembly (100). The north pole and the south pole of the plurality of magnets (200a, 200b) is provided adjacent to each other for providing efficient magnetic flux lines with minimal intervention of external noise and vibrations. The at least one stator (108) and the at least one rotor (106a, 106b) are formed by stacking a plurality 25 of laminated metal sheets with each other and then pressed together to form the at least one stator (108) and the at least one rotor (106a, 106b). The at least one stator (108) is configured to have a plurality of slots (204) for aligning with the plurality of magnets (200a, 200b) of the at least one rotor (106a, 106b). The at least one stator (108) comprising a plurality of magnetic coils (202) wound around each of the 30 plurality of slots (204) for generating magnetic flux.
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[052] Figure 3 illustrates a cross section view of the motor assembly (100) along a vertical axis, in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter. The at least one stator (108) and the at least one rotor (106a, 106b) is disposed coaxially and concentrically on the motor shaft (110). The at least one stator (108) and the at least one rotor (106a, 5 106b) are disposed at an air gap (300a, 300b). The air gap (300a, 300b) is uniform between the at least one stator (108) and the at least one rotor (106a, 106b) and in one embodiment, the air gap (300a, 300b) is a predetermined air gap being in the range of 0.65mm and 1mm.
[053] In one embodiment, the distance and clearance between an outer boundary 10 (not shown) of the at least one rotor (106a, 106b) and an inner periphery (not shown) of the housing (102a, 102b) is equal to the air gap (300a, 300b). This configuration enables maintenance of uniform air gap and thereby reduce the vibration losses and noises from the motor assembly (100). This configuration further aids in reducing complexity in the design of the motor assembly (100). 15
[054] Figure 4 illustrates a front view of the at least one stator (108) of the motor assembly (100), in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter. The at least one stator (108) is configured to have a plurality of protrusions (500). The plurality of protrusions (500) are crescent shaped in one embodiment, and the plurality of 20 protrusions (500) are disposed along one or more peripheral edges (508) of the at least one stator (108). The plurality of protrusions (500) are disposed at a predetermined angle from each other, and the predetermined angle being in a range from 120 degrees to 360 degrees. In a preferred embodiment, the plurality of protrusions (500) are disposed in an angle of 120 degrees. 25
[055] Furthermore, each of the plurality of protrusions (500) is provided with a groove (502a, 502b). The grooves (502a, 502b) being configured to extend outwards from a peripheral end (502) of the each of the plurality of protrusions (500). The each of the plurality of protrusions are provided with one or more first holes (504) for affixing the at least one stator (108) to the housing (102a, 102b). 30
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[056] Figure 5a illustrates a front view of the housing (102a, 102b) of the motor assembly (100), in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter. Figure 5b illustrates a left perspective view of the housing (102a, 102b) of the motor assembly (100), in accordance with an embodiment of the present subject matter, in accordance with an 5 embodiment of the present subject matter. The housing (102a, 102b) of the motor assembly (100) is configured to accommodate the at least one stator (108). In one embodiment, one of the housing (102a, 102b) is configured to include a plurality of inner protrusions (600). The plurality of inner protrusions (600) is also disposed at the predetermined angle and the plurality of inner protrusions (600) is configured to 10 conform in shape and profile with the plurality of protrusions (500) of the at least one stator (108). The plurality of inner protrusions (600) are provided at the inner periphery of the housing (102a, 102b) for accommodating the plurality of protrusions (500) of the at least one stator (108).
[057] The plurality of inner protrusions are provided at a clearance height (H1) 15 and the clearance height (H1) is between 150 to 300 microns. The plurality of inner protrusions (600) is provided with a first end (610a) and a second end (not shown). The second end is a stopper (610) and the stopper (610) is also disposed at the clearance height (H1). The first end (610a) is open and is configured to receive the plurality of protrusions (500) of the at least one stator (108) and the stopper (610) is 20 configured to arrest and stop the movement of the at least one stator (108) when disposed inside the housing (102a, 102b).
[058] The plurality of inner protrusions (600) are provided with one or more second holes (604). The one or more second holes (604) of the plurality of inner protrusions (600) and the one or more first holes (504) of the plurality of protrusions 25 (500) of the at least one stator (108) conform with each other and are fastened together with the one or more fasteners (112). In one embodiment, the each of the plurality of inner protrusions (600) of the housing (102a, 102b) is configured to have a depression (602a, 602b). The depression (602a, 602b) is disposed at the one of the first end (610a) and the second end of the plurality of inner protrusions (600) of the 30 housing (102a, 102b). The depression (602a, 602b) of the plurality of inner
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protrusions (600) of the housing (102a, 102b) is configured to interlock with the groove (502a, 502b) of the each of the plurality of protrusions (500) of the at least one stator (108). The interlocking between the groove (502a, 502b) and the depression (602a, 602b) is configured to lock the at least one stator (108) inside the housing (102a, 102b) and thereby restrict and arrest the movement of the at least one 5 stator (108). [059] Figure 6 illustrates a front perspective view of the at least one stator (108) disposed in the housing (102a, 102b) of the motor assembly (100), in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter. The at least one stator (108) is disposed 10 inside the housing (102a, 102b) and is locked in the plurality of inner protrusions (600) of the housing (102a, 102b). In one embodiment, the at least one stator (108) is rotated at a predetermined angle to lock the at least one stator (108) in the housing (102a, 102b). In one embodiment, the predetermined angle is between 120 degrees to 360 degrees. 15
[060] Figure 7 illustrates a front view of the at least one stator (108) being abutted inside the housing (102a, 102b) of the motor assembly (100), in accordance with an embodiment of the present subject matter, in accordance with an embodiment of the present subject matter. A method of assembling the motor assembly (100) comprises the following steps. Firstly, assembling one of at least one 20 rotor (106a, 106b) in the housing (102a, 102b) of the motor assembly (100). Secondly, assembling the motor shaft (110) by configuring the motor shaft (110) to pass through one of the at least one rotor (106a, 106b). Thirdly, connecting a second rotor of the at least one rotor (106a, 106b) through the motor shaft (110) and the at least one rotor (106a, 106b) is enveloped inside the housing (102a, 102b). 25
[061] Fourthly, assembling at least one stator (108) on the motor shaft (110) through an outer diameter of the motor shaft (110). Fifthly, aligning the plurality of protrusions (500) of the at least one stator (108) by the housing (102a, 102b) for mating of the plurality of protrusions (500) with the plurality of inner protrusions (600) of the housing (102a, 102b). Sixthly, rotating the at least one stator (108) at a 30 predetermined angle and locking the plurality of protrusions (500) of the at least one
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stator (108) inside the plurality of inner protrusions (600) of the housing (102a, 102b). Finally, securing the plurality of protrusions (500) of the at least one stator (108) to the plurality of inner protrusions (600) of the housing (102a, 102b) through the one or more fasteners (112). [062] In one embodiment, the at least one stator (108) is rotated in a clockwise 5 direction as shown in the illustrated states (A, B, C) for locking the at least one stator (108) in the plurality of inner protrusions (600) of the housing (102a, 102b) of the motor assembly (100). A method of assembling the motor assembly (100) comprising the steps. Firstly, assembling one of the at least one rotor (106a, 106b) in the housing (102a, 102b) of said motor assembly (100). Thereafter, assembling 10 the motor shaft (110), and the motor shaft (110) being configured to pass through one of the at least one rotor (106a, 106b). Further connecting the second rotor (106b) of the at least one rotor (106a, 106b) through the motor shaft (110) and the at least one rotor (106a, 106b) being enveloped inside the housing (102a, 102b). Then, assembling the at least one stator (108) on the motor shaft (110) through an outer 15 diameter of the motor shaft (110). Further, aligning the plurality of protrusions (500) of the at least one stator (108) with the housing (102a, 102b) for mating of the plurality of protrusions (500) with the plurality of inner protrusions (600) of the housing (102a, 102b). Further, rotating the at least one stator (108) at the predetermined angle and locking the plurality of protrusions (500) of the at least one 20 stator (108) inside the plurality of inner protrusions (600) of the housing (102a, 102b). Finally, securing the plurality of protrusions (500) of the at least one stator (108) to the plurality of inner protrusions (600) of the housing (102a, 102b) through the one or more fasteners (112).
[063] Various embodiments of the invention provides a motor assembly and a 25 method for assembling the motor assembly. The motor assembly comprises at least one stator and at least one rotor being disposed inside a housing of the motor assembly. The housing of the motor assembly comprising one or more locking provisions to arrest translational and rotational movements of the at least one stator for maintaining uniform air gap between the at least one stator and the at least one 30 rotor and also for enhancing the overall power density of the motor assembly.
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[064] The present invention is a motor assembly comprising at least one stator, at least one rotor, and a housing. The at least one stator and the at least one rotor is provided inside the housing. The at least one stator and the at least one rotor is disposed together for maintaining an air gap between the at least one stator and the at least one rotor. Further, one of the at least one stator and the at least one rotor is 5 abutted to the housing for arresting movement of the at least one stator.
[065] The present claimed invention solves the technical problem of non-uniform air gap between the at least one stator and the at least one rotor and thereby reduce the vibrational losses during assembly of the motor assembly and inadvertently increase the overall power density of the motor assembly. 10
[066] Specifically, the claimed motor assembly has high power density and low volume in the construction of the axial motor assembly. Further the claimed motor assembly maintains uniform gap between the at least one rotor and the at least one stator during the overall movement of the motor assembly.
[067] Additionally, the configuration of the plurality of protrusions of the at least 15 one stator abutting with the plurality of inner protrusions of the housing provides an interlocking mechanism of the at least one stator in the housing and thereby arrests any movement of the at least one stator during the motion of the motor assembly.
[068] Furthermore, the grooves and the depressions of the plurality of protrusions and the plurality of inner protrusions respectively provides a seamless 20 finish and prevents ease of alignment and interlocking of the at least one stator and the housing without use of any complex tools.
[069] The present invention also provides advantages of ease of assembly of the motor assembly by simply rotating the at least one stator at a predetermined angle and thereby eliminates the use of complex tools and assembly techniques. 25
[070] In light of the above-mentioned advantages and the technical advancements provided by the disclosed motor assembly comprising the at least one stator being abutted in the housing, the claimed invention as discussed above is not routine, conventional, or well understood in the art, as the claimed invention enable the following solutions to the existing problems in conventional technologies. 30 Further, the claimed invention clearly bring an improvement in the configuration and
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construction of the at least one stator and the at least one rotor being abutted to the housing for maintaining uniform air gap in the motor assembly as the claimed invention provide a technical solution to a technical problem. [071] While the present invention has been shown and described with reference to the foregoing preferred embodiments, it will be apparent to those skilled in the art 5 that changes in form, connection, and detail may be made therein without departing from the spirit and scope of the invention.
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Reference Numerals:
100 motor assembly
102a, 102b housing 5
104a, 104b first and second bearing
106a, 106b at least one rotor
108 at least one stator
110 motor shaft
112 one or more fasteners 10
114a one or more reduction gears
114b, 114c, 114d, 114e one or more bearings and fasteners
200a, 200b plurality of magnets
202 plurality of magnetic coils
204 plurality of slots 15
300a, 300b air gap
500 plurality of protrusions
502a, 502b grooves
504 one or more first holes
508 peripheral edges 20
600 plurality of inner protrusions
602a, 602b depression
604 one or more second holes
610 stopper
610a first end , Claims:I/We claim:
1. A motor assembly (100) comprising:
at least one stator (108);
at least one rotor (106a, 106b); and
a housing (102a, 102b); 5
wherein said at least one stator (108) and said at least one rotor (106a, 106b) being provided inside said housing (102a, 102b), and
wherein said at least one stator (108) and said at least one rotor (106a, 106b) being disposed together for maintaining an air gap (300a, 300b) between said at least one stator (108) and said at 10 least one rotor (106a, 106b); and
wherein said at least one stator (108) being abutted to said housing (102a, 102b) for arresting movement of said at least one stator (108).
2. The motor assembly (100) as claimed in claim 1, wherein said at least one 15 stator (108) being sandwiched between said at least one rotor (106a, 106b), and wherein said at least one stator (108) and said at least one rotor (106a, 106b) being disposed on a motor shaft (110).
3. The motor assembly (100) as claimed in claim 1, wherein said at least one stator (108) being configured to have a plurality of protrusions (500), said 20 plurality of protrusions (500) being disposed along one or more peripheral edges (508) of said at least one stator (108).
4. The motor assembly (100) as claimed in claim 1, wherein said at least one rotor (106a, 106b) being configured to have a first diameter D1.
5. The motor assembly (100) as claimed in claim 1, wherein said at least one 25 stator (108) being configured to have a second diameter D2, said second diameter D2 being greater than said first diameter D1.
6. The motor assembly (100) as claimed in claim 1, wherein said at least one stator (108) being disposed between said at least one rotor (106a, 106b) with
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a predetermined air gap, said predetermined air gap being between 0.65 mm to 1mm.
7. The motor assembly as claimed in claim 1, wherein said at least one rotor (106a, 106b) being disposed between said at least one stator (108) with said predetermined air gap, said predetermined air gap being between 0.65mm 5 to 1mm.
8. The motor assembly (100) as claimed in claim 1, wherein said housing (102a, 102b) being configured to have a plurality of inner protrusions (600), said plurality of inner protrusions (600) being configured to conform in shape and profile with said plurality of protrusions (500) of said at least one 10 stator (108).
9. The motor assembly as claimed in claim 8, wherein said plurality of inner protrusions (600) being disposed on an inner periphery of one of said housing (102a, 102b), wherein said plurality of inner protrusions (600) being disposed at a predetermined angle, wherein said plurality of 15 protrusions (500) of said at least one stator (108) being disposed at said predetermined angle, wherein said predetermined angle being in a range of 120 to 360 degrees.
10. The motor assembly (100) as claimed in claim 1, wherein said housing (102a, 102b) being configured to envelop said at least one stator (108) and 20 said at least one rotor (106a, 106b).
11. The motor assembly (100) as claimed in claim 6, wherein said plurality of inner protrusions (600) being provided a clearance height (H1), wherein said clearance height (H1) being between 150-300 microns.
12. The motor assembly (100) as claimed in claim 8, wherein said plurality of 25 inner protrusions (600) comprising a stopper (610), said stopper (610) disposed at one end (610a) of said plurality of inner protrusions (600), and said stopper (610) being configured to have clearance height H1 being between 150-300 micron.
13. The motor assembly (100) as claimed in claim 3, wherein each of said 30 plurality of protrusions (500) of said at least one stator (108) being
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configured to have a groove (502a, 502b), said groove (502a, 502b) being disposed at one peripheral end (502) of said each of said plurality of protrusions (500) of said at least one stator (108).
14. The motor assembly (100) as claimed in claim 13, wherein said each of said plurality of protrusions (500) being configured to be crescent shaped. 5
15. The motor assembly (100) as claimed in claim 6, wherein each of said plurality of inner protrusions (600) of said housing (102a, 102b) being configured to have a depression (602a, 602b), said depression (602a, 602b) being disposed at said one end (610a) of said plurality of inner protrusions (600) of said housing (102a, 102b). 10
16. The motor assembly (100) as claimed in claim 15, wherein said depression (602a, 602b) of said plurality of inner protrusions (600) of said housing (102a, 102b) being configured to interlock with said groove (502a, 502b) of said each of said plurality of protrusions (500) of said at least one stator (108), wherein said interlocking between said groove (502a, 502b) and said 15 depression (602a, 602b) being configured to lock said at least one stator (108) inside said housing (102a, 102b).
17. The motor assembly (100) as claimed in claim 14, wherein said plurality of protrusions (500) of said at least one stator (108) being fastened to said plurality of inner protrusions (600) of said housing (102a, 102b) using one 20 or more fasteners (112), said one or more fasteners (112) being fastened through one or more first holes (504) and through one or more second holes (604), wherein said one or more first holes (504) being disposed on said plurality of protrusions (500) of said at least one stator (108) and said one or more second holes (604) being disposed on said plurality of inner 25 protrusions (600) of said housing (102a, 102b).
18. The motor assembly (100) as claimed in claim 1, wherein said air gap (300a, 300b) being equal to a clearance between said inner periphery of said housing (102a, 102b) and said one or more rotors (106a, 106b), wherein said clearance being in range of 0.65 mm to 1mm. 30
19. A method of assembling a motor assembly (100) comprising the steps of:
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assembling, one of at least one rotor (106a, 106b) in a housing (102a, 102b) of said motor assembly (100);
assembling a motor shaft (110), said motor shaft (110) being configured to pass through said one of said at least one rotor (106a, 106b);
connecting a second rotor of said at least one rotor (106a, 106b) 5 through said motor shaft (110) and said at least one rotor (106a, 106b) being enveloped inside said housing (102a, 102b);
assembling at least one stator (108) on said motor shaft (110) through an outer diameter of said motor shaft (110);
aligning plurality of protrusions (500) of said at least one stator (108) 10 by said housing (102a, 102b) for mating of said plurality of protrusions (500)with plurality of inner protrusions (600) of said housing (102a, 102b);
rotating said at least one stator (108) at a predetermined angle andlocking said plurality of protrusions (500) of said at least one stator (108) inside said plurality of inner protrusions (600) of said housing (102a, 102b); 15 and
securing said plurality of protrusions (500) of said at least one stator (108)to said plurality of inner protrusions (600) of said housing (102a,102b) through one or more fasteners (112).
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Dated 19 day of July 2023