Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
2000-07-10
2001-05-15
Ramirez, Nestor (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S089000, C310S049540, C310S043000, C310S06700R, C310S071000, C310S254100, C310S257000, C310S164000
Reexamination Certificate
active
06232687
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates generally to electric motors and more particularly to an electric motor having a simplified, easily assembled construction.
Assembly of electric motors requires that a rotor be mounted for rotation relative to a stator so that magnets on the rotor are generally aligned with one or more windings on the stator. Conventionally, this is done by mounting a shaft of the rotor on a frame which is attached to the stator. The shaft is received through the stator so that it rotates about the axis of the stator. The frame or a separate shell may be provided to enclose the stator and rotor. In addition to these basic motor components, control components are also assembled. An electrically commutated motor may have a printed circuit board mounting various components. Assembly of the motor requires electrical connection of the circuit board components to the winding and also providing for electrical connection to an exterior power source. The circuit board itself is secured in place, typically by an attachment to the stator with fasteners, or by welding, soldering or bonding. Many of these steps are carried out manually and have significant associated material labor costs. The fasteners, and any other materials used solely for connection, are all additional parts having their own associated costs and time needed for assembly.
Tolerances of the component parts of the electric motor must be controlled so that in all of the assembled motors, the rotor is free to rotate relative to the stator without contacting the stator. A small air gap between the stator and the magnets on the rotor is preferred for promoting the transfer of magnetic flux between the rotor and stator, while permitting the rotor to rotate. The tolerances in the dimensions of several components may have an effect on the size of the air gap. The tolerances of these components are additive so that the size of the air gap may have to be larger than desirable to assure that the rotor will remain free to rotate in all of the motors assembled. The number of components which affect the size of the air gap can vary, depending upon the configuration of the motor.
Motors are commonly programmed to operate in certain ways desired by the end user of the motor. For instance certain operational parameters may be programmed into the printed circuit board components, such as speed of the motor, delay prior to start of the motor, and other parameters. Mass produced motors are most commonly programmed in the same way prior to final assembly and are not capable of re-programming following assembly. However, the end users of the motor sometimes have different requirements for operation of the motor. In addition, the end user may change the desired operational parameters of the motor. For this reason, large inventories of motors, or at least programmable circuit boards, are kept to satisfy the myriad of applications.
Electric motors have myriad applications, including those which require the motor to work in the presence of water. Water is detrimental to the operation and life of the motor, and it is vital to keep the stator and control circuitry free of accumulations of water. It is well known to make the stator and other components water proof. However, for mass produced motors it is imperative that the cost of preventing water from entering and accumulating in the motor be kept to a minimum. An additional concern when the motor is used in the area of refrigeration is the formation of ice on the motor. Not uncommonly the motor will be disconnected from its power source, or damaged by the formation of ice on electrical connectors plugged into the circuit board. Ice which forms between the printed circuit board and the plug-in connector can push the connector away from the printed circuit board, causing disconnection, or breakage of the board or the connector.
SUMMARY OF THE INVENTION
Among the several objects and features of the present invention may be noted the provision of an electric motor which has few component parts; the provision of such a motor which does not have fasteners to secure its component parts; the provision of such a motor which can be accurately assembled in mass production; the provision of such a motor having components capable of taking up tolerances to minimize the effect of additive tolerances; the provision of such a motor which can be re-programmed following final assembly; the provision of such a motor which inhibits the intrusion of water into the motor; and the provision of such a motor which resists damage and malfunction in lower temperature operations.
Further among the several objects and features of the present invention may be noted the provision of a method of assembling an electric motor which requires few steps and minimal labor; the provision of such a method which minimizes the number of connections which must be made; the provision of such a method which minimizes the effect of additive tolerances; the provision of such a method which permits programming and testing following final assembly; and the provision of such a method which is easy to use.
Generally, a method of assembling an electric motor of the present invention comprises forming a stator including a stator core and a winding wound on the stator core and forming a rotor including a shaft. A housing is formed which is adapted to support and at least partially enclose the stator and rotor. The rotor is mounted on the stator by inserting the shaft through the stator for rotation relative to the stator about a longitudinal axis of the rotor shaft. The stator/rotor subassembly so formed is snap connected to the housing.
In another aspect of the present invention, an electric motor generally comprises a stator including a stator core, a winding on the stator core, and a first snap connector element. A rotor including a shaft is received in the stator core for rotation of the rotor relative to the stator about the longitudinal axis of the shaft. A housing adapted to support the stator and rotor has a second snap connector element formed therein. The first snap connector element is engaged with the second snap connector element for connecting the stator and rotor to the housing.
Other objects and features of the present invention will be in part apparent and in part pointed out hereinafter.
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Bobay Dennis P.
Golm, Jr. Norman
Grimm James E.
Hall Jeffrey A.
Hollenbeck Robert K.
Dinh Le Dang
General Electric Company
Ramirez Nestor
Senniger Powers Leavitt & Roedel
Wasserbauer Damian
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