Description:A STATOR ASSEMBLY FOR A MOTOR
TECHNICAL FIELD
[0001] The present subject matter generally relates to a stator assembly for a motor in a vehicle. More specifically, the present subject matter provides an improved and light weight and compact stator assembly.
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BACKGROUND
[0002] Electric vehicles, such as two-wheeler vehicles, have a hub motor that includes a rotor assembly and a stator assembly. The stator assembly is stationary part of the motor. Major parts of such a stator assembly include a shaft, a hub, a spider, stator lamination, windings, etc. Typically, the spider is 10 made up of heavy sheet metal, particularly, the existing spider is made of punched steel sheets which are welded each other and to a hub. The existing hub is mount on to the shaft through welding. The stator lamination is mounted on the spider. This arrangement causes poor performance of the stator assembly due to its higher weight. Moreover, the punched steel sheets construction of the 15 spider leads to a significantly heavier spider, increasing weight of the spider and of the vehicle , which slows in turn increases power consumption and gives poor range of the vehicle. Another drawback with the existing stator assembly is the welding issues. Welding of the punched steel sheets together and to the hub is complex process, and sometimes done poorly, leading to weak spots or cracks, 20 i.e. potential quality control issues. Further, due to limited manufacturing aids, it's hard to make the spider lighter, stronger, or have special features. These problems can make the motor heavier, less efficient, and more expensive.
[0003] As the existing design of the spider consists of punched steel sheets into shape and welded to the hub, she steel is a heavy material, and using 25 multiple sheets adds up, making the entire spider much heavier. This extra weight makes the motor bulkier and less efficient, especially for applications like electric vehicles where weight matters a lot. In addition, welding introduces several challenges, such as it requires expertise and specific equipment, making
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manufacturing more complex and expensive. Further, the punched steel sheet method restricts design flexibility, ability to create intricate shapes or optimize the structural integrity. Another drawback is that steel has moderate thermal conductivity, and the welded joints can further impede heat transfer. The complex geometry of the spider may also limit heat flow. Welds can create 5 stress concentration points, and the weight of the steel spider can put additional strain on the structure. [0004] Thus, there arises a need for a stator assembly for a hub motor, which can overcome above mentioned disadvantages.
[0001] Further limitations and disadvantages of conventional and 10 traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.
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SUMMARY
[0002] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed 20 description.
[0003] According to embodiments illustrated herein, the present disclosure provides a stator assembly for an electric motor, particularly a hub motor. The stator assembly comprises a spider and a mounting member. The mounting member is coupled to the spider and is configured to mount the spider on a long 25 member. Herein, the mounting member is made up of a first material and the spider is made up of a second material. The second material is dissimilar from the first material.
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[0004] In an embodiment, the mounting member is made up of steel and the spider is made up of aluminium, i.e. the
first material is steel and the second material is aluminium.
[0005] In an embodiment, the mounting member is coupled to the long member through a first locking mechanism including at least one key and at 5 least one slot.
[0006] In an embodiment, the stator assembly comprises a laminating member. The laminating member is coupled to the spider through one or more connecting pins.
[0007] In an embodiment, the one or more connecting pins is configured 10 between one or more first slots provided in the laminating member and one or more second slots provided in the spider.
[0008] In an embodiment, the stator assembly comprises a plurality of insulating rings configured with the laminating member. Each of the insulating rings comprises a plurality of first projections extended from an outer end and 15 abut with the laminating member and one or more second projections extended from an inner end to engage with the spider.
[0009] In an embodiment, the spider comprises at least one stopper projection on at least one side of the spider.
[00010] In an embodiment, the mounting member having an opening 20 extending along length of the mounting member to receive the long member.
[00011] In an embodiment, the mounting member comprises any or a combination of one or more first grooves and one or more first protrusions and the spider comprises any or a combination of one or more second grooves and one or more second protrusions. 25
[00012] In an embodiment, the spider is molded over the mounting member, , the unit/combination of the mounting member and the spider is mounted on the long member through the first locking mechanism.
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BRIEF DESCRIPTION OF DRAWINGS
[00013] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which 5 are given by way of illustration only, and thus are not limitative of the present invention.
[00014] The detailed description is described with reference to the accompanying figures, which is related to a start assembly for a motor in a vehicle which is a two-wheeled vehicle being one embodiment of the present 10 subject matter. However, the present subject matter is not limited to the depicted embodiment(s). In the figures, the same or similar numbers are used throughout to reference features and components.
[00015] Fig. 1 illustrates a perspective view of a stator assembly, in accordance with an embodiment of the present subject matter. 15
[00016] Fig. 2 illustrates an exploded view of the stator assembly, in accordance with an embodiment of the present subject matter.
[00017] Fig. 3 illustrates a perspective view of a mounting member and a spider of the stator assembly, in accordance with an embodiment of the present subject matter. 20
[00018] Fig. 4 illustrates a perspective view of the stator assembly and an enlarged view of one or more second slots to receive connecting pins, in accordance with an embodiment of the present subject matter.
[00019] Fig. 5 illustrates a perspective view of the mounting member of the stator assembly, in accordance with an embodiment of the present subject 25 matter.
[00020] Fig. 6 illustrates a top and a side view of the mounting member of the stator assembly, in accordance with an embodiment of the present subject matter.
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DETAILED DESCRIPTION
[00021] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect 5 to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented, and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular 10 implementation choices in the following embodiments described and shown.
[00022] 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, 15 adaptations, and other implementations are possible without departing from the spirit and scope of the disclosed embodiments. It is intended that the following detailed description be considered as exemplary only, with the true scope and spirit being indicated by the following claims.
[00023] References to “one embodiment,” “at least one embodiment,” “an 20 embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the 25 phrase “in an embodiment” does not necessarily refer to the same embodiment.
[00024] The present invention now will be described more fully hereinafter with different embodiments. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather those embodiments are provided so that this disclosure 30
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will be thorough and complete, and fully convey the scope of the invention to those skilled in the art. [00025] The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate 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.
[00026] Various features and embodiments of the present subject matter here 10 will be discernible from the following further description thereof, set out hereunder. It is contemplated that the concepts of the present subject matter may be applied to any kind of vehicle within the spirit and scope of this subject matter. The detailed explanation of the constitution of parts other than the present subject matter which constitutes an essential part has been omitted at 15 suitable places.
[00027] It is an object of the present invention to provide a stator assembly for a motor, particularly a hub motor for an electric vehicle, which is compact, lightweight and performs with higher efficiency. It is also an object of the present invention to provide a spider that is made up of light metals which 20 enhances performance of the stator assembly due to its lesser weight. It is also an object of the present invention to reduce spider, thereby reducing power consumption and increasing a range of the vehicle. Another object of the present invention is to simplify and improve the manufacturing process. Thus, the object of the present invention is to provide light weight spider which can 25 enhance performance of the hub motor. It is also an object of the present invention to provide lighter motors, improved efficiency, and less prone to breaking. It is also an object of the present invention to provide less bulky and more efficient stator assembly especially for applications like electric vehicles where weight matters a lot. It is also an object of the present invention to avoid 30
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challenges that come due to welding of steel metals and therefore the object is to ease manufacturing process and provide more flexibility in designs. Another object is to provide better heat dissipation by using metals which have more thermal expansion. Thus, the object of the present invention is to increase the durability and reliability of the spider. 5 [00028] The present subject matter along with all the accompanying embodiments and their other advantages would be described in greater detail in conjunction with the figures in the following paragraphs.
[00029] The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely 10 illustrate principles of the present subject matter. Various arrangements may be 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. 15
[00030] The present subject matter may be implemented in any two-wheeled, three-wheeled and four-wheeled vehicle. However, for the purpose of explanation and by no limitation, the present invention, and corresponding additional advantages and features are described through the following embodiments depicting a two wheeled vehicle. 20
[00031] In an embodiment, the vehicle may be a bike cum scooter type vehicle and may have main frame that extends along the center of the body of the vehicle from a front portion of the vehicle and extending in a rearwardly direction.
[00032] In an embodiment, the vehicle may be a two-wheeled vehicle and 25 may have main frame that extends along the center of the body of the vehicle from a front portion of the vehicle and extending in a rearwardly direction.
[00033] Fig. 1 illustrates a perspective view of a stator assembly (100), in accordance with an embodiment of the present subject matter. Fig. 1 further
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illustrates parts and components of the stator assembly (100) in an assembled view. The stator assembly (100) comprises various components including a hub (herein referred as mounting member) (102), a spider (104), plurality of insulating rings (106), a laminating member (110), a winding member (112), a connecting shaft (herein referred as long member) (108), and a key (202) 5 (shown in Fig. 2). [00034] Fig. 2 illustrates an exploded view of the stator assembly (100), in accordance with an embodiment of the present subject matter. The exploded view of the stator assembly (100) illustrates each of the components of the stator assembly (100) in detail. The spider (104) is the stationary part that holds 10 the stator laminations (herein referred as the laminating member) (110). In an embodiment, the spider (104) is made up of aluminum that offers lighter weight and improved heat dissipation. The mounting member (102) also known as hub is the central component of the stator assembly (100), connecting the spider (104) to the connecting shaft (herein referred as the long member) 15 (108). In an embodiment, the mounting member (102) is made from steel for strength and durability. In one embodiment, the plurality of insulating rings (106) are thin rings made of insulating materials like kapton or mylar. The plurality of insulating rings (106) is placed with the laminating member (110) to prevent electrical shots and reduce eddy 20 currents. In one embodiment, the plurality of insulating rings (106) can be pre-formed or applied as tape during assembly. In an embodiment, the
plurality of insulating rings (106) configured with the laminating member (110) and the winding member (112) is configured over the insulating rings (106). Each of the insulating rings (106) comprises a plurality of first projections (106f) 25 extended from an outer end (106o) and abut with the laminating member (110) and one or more second projections (106s) extended from an inner end (106i) to engage with the spider (104).
[00035] The laminating member (110) is the core of the stator assembly (100). In one embodiment, the laminating member (110) can be made from thin 30
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stacks of steel sheets electrically insulated from each other. The laminating member (110) creates a path for the magnetic field generated by windings. Generally, the number of poles and winding configuration determine motor's torque and speed characteristics. The long member (108) also known as connecting shaft connects the motor to the wheel or drive axle. The long 5 member (108) transfers the torque generated by the motor to propulsion system. In one embodiment, the long member (108) is made from high-strength steel to withstand the torque and bending loads. The mounting member (102) is coupled to the long member (108) through a first locking mechanism including a key (202) and slot (202s). The key (202) is a wedge-shaped piece that fits into 10 slots provided on the long member (108) and the mounting member (102). The key (202) prevents the mounting member (102) from rotating on the long member (108). In one embodiment, the key (202) is made from steel. [00036] Fig. 3 illustrates a perspective view of the mounting member (102) and the spider (104) of the stator assembly (100), in accordance with an 15 embodiment of the present subject matter. In one embodiment, the spider (104) is provided with one or more second slots (302) to receive the connecting pins (204). In an embodiment, the spider (104) comprises at least one stopper projection on at least one side of the spider (104). The other side of the spider (104) is hammered down to have a stopping feature on outer edge of the spider 20 (104) to prevent axial movement of the spider (104).
[00037] In an embodiment, the mounting member (102) can include one or more first grooves (505).
[00038] In another embodiment, the mounting member (102) can include one or more first protrusions (605). 25
[00039] In an embodiment, the spider (104) comprises one or more second grooves (not shown)
[00040] In another embodiment, the spider (104) can comprise one or more second protrusions. In a working example, if the mounting member (102) is
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having groves, then the spider (104) will be having protrusions to engage with the grooves of the mounting member (102). In another working example, if the mounting member (102) is having protrusion, then the spider (104) will be having grooves to receive the protrusions of the mounting member (102). Thus, grooves of either the mounting member (102) or the spider (104) engage with 5 the protrusions of the spider (104) or the mounting member (102) respectively. In one embodiment, the spider (104) is molded over the mounting member (102) and after molding, combination of the mounting member (102) and the spider (104) is mounted on the long member (108) through a key (202). [00041] In another embodiment, the mounting member (102) can comprise 10 a combination of the first grooves (505) and the first protrusions (605) and the spider (104) can comprise a combination of the second grooves and the second protrusions to couple with each other.
[00042] Fig. 4 illustrates a perspective view of the stator assembly (100) and an enlarged view of one or more second slots (shown in Fig. 3) to receive one 15 or more connecting pins (204), in accordance with an embodiment of the present subject matter. Fig. 3 clearly illustrates the one or more connecting pins (204) between one or more first slots provided in the laminating member (110) and one or more second slots (302) provided in the spider (104). The one or more second slots (302) provided in the spider (104) is along circumferential length 20 of outer periphery of the spider (104). This will arrest the relative circumferential movement between the spider (104) and the laminating member (110). Fig. 4 also depicts other components of the stator assembly (100) like the long member (108), the mounting member (102), and the winding member (112). In an embodiment, combination of the mounting member (102), the 25 spider (104), the laminating member (110), works together as one integrated unit. Ina n embodiment, the winding member (112) connected with the laminating member (110).
[00043] Fig. 5 illustrates a perspective view of the mounting member (102) of the stator assembly (100), in accordance with an embodiment of the present 30
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subject matter. Fig. 5 illustrates that the mounting member (102) is having an opening (502) extending along length of the mounting member (102) to receive the long member (108). The mounting member (102) also has one or more first grooves (505) to engage with the spider (104). [00044] In an embodiment, the mounting member (102) is provided with a 5 furrow (510) along circumference of outer periphery of the mounting member (102). The furrow (510) is provided strategically to reduce material and weight of the mounting member (102).
[00045] Fig. 6 illustrates a top and side view of the mounting member (102) of the stator assembly (100), in accordance with an embodiment of the present 10 subject matter. Fig. 6 clearly illustrates that the mounting member (102) has one or more first protrusions (605) on outer circumference of the mounting member (102) to engage with the spider (104). In an embodiment, the mounting member (102) comprises any or a combination of one or more first grooves (505) and one or more first protrusions (605). 15
[00046] Thus, the present subject matter offers an advantage of providing a stator assembly for a motor which is compact, lightweight and has higher efficiency. Another advantage of the present invention is that the spider is made up of light metals which enhances performance of the stator assembly due to its lesser weight. Another advantage of the present invention is having reduced 20 weight in the spider which reduces power consumption and gives a higher range of the vehicle. Another advantage of the present invention is simplification and improvement in the manufacturing process. Thus, the advantage of the present invention is having the stator assembly which has light weight spider which can enhance performance of stator assembly. It is also an advantage of the present 25 invention to have lighter motors, improved efficiency, and less prone to breaking. It is also an advantage of the present invention to have less bulky and more efficient stator assembly especially for applications like electric vehicles where weight matters a lot. It is also an advantage of the present invention to have ease in the manufacturing process and thus have more flexibility in 30
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designs. Another advantage is having better heat dissipation by using metals which have more thermal expansion. Another advantage of the present invention is avoiding corrosion and weakening of metals with time as aluminum is used. Thus, the advantage of the present invention is to increase the durability and reliability of the spider and in turn the stator assembly. Unlike conventional 5 aluminum spiders, present subject matter introduces a sophisticated dowel and stopper concept, ensuring a secure connection with stator laminations and minimizing movement. Additionally, the disc-type structure of aluminum spider enhances structural integrity and streamlines manufacturing processes. These innovations address limitations in both traditional sheet metal spiders and 10 known aluminum designs, making present invention more comprehensive and superior in terms of performance and reliability. [0001] While certain features of the claimed subject matter have been illustrated and described herein, many modifications, substitutions, changes, and equivalents will now occur to those skilled in the art. It is, therefore, to be 15 understood that the appended claims are intended to cover all such modifications and changes that fall within the true spirit of the claimed subject matter.
[0002] In light of the abovementioned advantages and the technical advancements provided by the disclosed subject matter, the claimed steps as 20 discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the functioning of the configuration itself as the claimed steps provide a technical solution to a technical problem. 25
[0003] The proposed solution's non-obviousness stems from its innovative combination of design elements, transcending the straightforward substitution of materials typically associated with weight reduction, typically 30-35% weight is reduced. The integration of an integrated unit design, where the mounting member (102) and spider (104) are cast together and securely affixed 30
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to the long member (108) using a key (202), ensures unparalleled stability by preventing relative movement. Additionally, the use of connecting pins (204) strategically connects the spider (104) to the laminating member (110), addressing circumferential movement issues. The axial restriction mechanism, featuring a stopper and roll-over, further distinguishes the invention by 5 providing a comprehensive solution beyond the expected material change. Together, these unique features represent a nuanced approach that goes beyond the conventional knowledge in the field, making the proposed solution non-obvious to a person skilled in the art. [0004] A description of an embodiment with several components in 10 communication with another does not imply that all such components are required, On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention.
[0005] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been 15 selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in 20 the following claims.
[0006] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit 25 being indicated by the following claims.
[0007] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may 30
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be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims. 5
Reference Numerals:
100 – stator assembly
102- mounting member 10
104- spider
106- insulation rings
108- long member
110- laminating member
112- winding member 15
202- key
302- slots
502- opening
505- grooves
510- furrow 20
605- protrusions , Claims:We claim:
1. A stator assembly (100) for a motor, the stator assembly (100) comprising:
a spider (104); and 5
a mounting member (102) coupled to the spider (104), the mounting member (102) being configured to mount the spider (104) on a long member (108);
wherein, the mounting member (102) being made up of a first material and the spider (104) being made up of a second material, the 10 second material being dissimilar from the first material.
2. The stator assembly (100) as claimed in claim 1, wherein the first material is steel and the second material is aluminium.
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3. The stator assembly (100) as claimed in claim 1, wherein the mounting member (102) being coupled to the long member (108) through a first locking mechanism including at least one key (202) and at least one slot (202s).
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4. The stator assembly (100) as claimed in claim 1 comprising a laminating member (110), the laminating member (110) being coupled to the spider (104) through one or more connecting pins (204).
5. The stator assembly (100) as claimed in claim 4, wherein the one or 25 more connecting pins (204) being configured between one or more first slots provided in the laminating member (110) and one or more second slots (302) provided in the spider (104).
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6.The stator assembly (100) as claimed in claim 4 comprising a pluralityof insulating rings (106) configured with the laminating member (110),each of the insulating rings (106) comprises a plurality of firstprojections (106f) extended from an outer end (106o) and abut with thelaminating member (110) and one or more second projections (106s)5 extended from an inner end (106i) to engage with the spider (104).
7.The stator assembly (100) as claimed in claim 1, wherein the spider(104)comprises at least one stopper projection on at least one side ofthe spider (104).10
8.The stator assembly (100) as claimed in claim 1, wherein the mountingmember (102) having an opening (502) extending along length of themounting member (102) to receive the long member (108).
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9.The stator assembly (100) as claimed in claim 1, wherein the mountingmember (102) comprises any or a combination of one or more firstgrooves (505) and one or more first protrusions (605), and wherein thespider (104) comprises any or a combination of one or more secondgrooves and one or more second protrusions.20
10.The stator assembly (100) as claimed in claim 1, wherein the spider(104)being molded over the mounting member (102).