Motor Design Power Tool Motor
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1 Motor Design Power Tool Motor
2 Power Tool Motor - Rationale Consumer demand for lighter weight cordless power tools Consumer demand for longer battery life for cordless power tools Consumer demand for higher torque/performance for cordless powder tool Redesign for minimum cost Redesign for maximum speed Redesign for minimum current
3 Benchmark Ferrite Power Tool Motor
4 Benchmark Ferrite Power Tool - Winding Details Winding Layout
5 Benchmark Ferrite Power Tool - Flux Scan Air gap flux for the magnetic circuit with solid iron piece replacing the armature of the motor
6 Benchmark Ferrite Power Tool - Dyno Test Characteristics of the motor measured using the dynamometer
7 Benchmark Ferrite Power Tool - FE Analysis B ac k E M F (V ) e e e e e Rotor Position (Degree) Flux line plot Back-emf of coils Torque (N-m m ) Rotor Position (Degree) Flux density plot Cogging torque
8 Benchmark Ferrite Power Tool - FE Analysis Developed torque at 72 A I armature (A) 72 A 13 A Magnet Original B2 B2-Inject Original B2 B2-Inject T average (N-mm/mm) T ripple (%) T average (%) T ripple (%)
9 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #1 (For Minimum Cost) Parameter Type of Magnet Total motor weight (gm) Length of the motor (mm) Overall diameter (mm) Total copper weight (gm) Total magnet weight (gm) Length of Air gap (mm) Current at 300 mn-m (A) Current at 600 mn-m (A) Efficiency at 300 mn-m (A) Efficiency at 600 mn-m (A) Benchmark PMDC Motor Ferrite Pole PMDC motor with Bonded Neo Magnets Compression Molded
10 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #1 (For Minimum Cost) Benchmarked Motor Redesigned Motor
11 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #1 (For Minimum Cost) Benchmarked Motor Exploded View of the Motor Redesigned Motor
12 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #1 (For Minimum Cost) Torque-Speed and Torque-Current Characteristics Torque-Efficiency Characteristics Speed (rpm ) Benchmarked Redesigned 90 Benchmarked Redesigned Speed Current Torque (mn-m) Torque (mn-m) Current (A) E f f ic ie n c y ( % )
13 of Physical Parameter and Cost Benchmark Ferrite Power Tool Vs Bonded Neo Concept #1 (For Minimum Cost) 2-Pole Ferrite 4-Pole Bonded Neo Diameter Length Weight Volume Cost
14 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #2 (For Maximum Speed) Parameter Type of Magnet Total motor weight (gm) Length of the motor (mm) Overall diameter (mm) Total copper weight (gm) Total magnet weight (gm) Length of Air gap (mm) Current at 300 mn-m (A) Current at 600 mn-m (A) Efficiency at 300 mn-m (A) Efficiency at 600 mn-m (A) Benchmark PMDC motor Ferrite Pole PMDC motor with Bonded Neo Magnets Compression Molded
15 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #2 (For Maximum Speed) Benchmarked Motor Redesigned Motor
16 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #2 (For Maximum Speed) Benchmarked Motor Exploded View of the Motor Redesigned Motor
17 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #2 (For Maximum Speed) Speed (rpm) Torque-Speed and Torque-Current Characteristics Speed Benchmarked Current Redesigned Torque (mn-m) Current (A) Efficiency (%) Torque-Efficiency Characteristics Benchmarked Redesigned Torque (mn-m)
18 of Physical Parameter and Cost Benchmark Ferrite Power Tool Vs Bonded Neo Concept #2 (For Maximum Speed) 2-Pole Ferrite 4-Pole Bonded Neo Diameter Length Weight Volume Cost
19 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #3 (For Minimum Current) Parameter Type of Magnet Total motor weight (gm) Length of the motor (mm) Overall diameter (mm) Total copper weight (gm) Total magnet weight (gm) Length of Air gap (mm) Current at 300 mn-m (A) Current at 600 mn-m (A) Efficiency at 300 mn-m (A) Efficiency at 600 mn-m (A) Benchmark PMDC motor Ferrite Pole PMDC motor with Bonded Neo Magnets Compression Molded
20 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #3 (For Minimum Current) Benchmarked Motor Redesigned Motor
21 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #3 (For Minimum Current) Benchmarked Motor Exploded View of the Motor Redesigned Motor
22 Benchmark Ferrite Power Tool Vs Bonded Neo Concept #3 (For Minimum Current) Torque-Speed and Torque-Current Characteristics Torque-Efficiency Characteristics Speed (rpm) Speed Current Benchmarked Redesigned Torque (mn-m) Current (A) Efficiency (%) Benchmarked Redesigned Torque (mn-m)
23 of Physical Parameter and Cost Benchmark Ferrite Power Tool Vs Bonded Neo Concept #3 (For Minimum Current) 2-Pole Ferrite 4-Pole Bonded Neo Diameter Length Weight Volume Cost
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