3D Flux Stator Assembly Using Spray-Formed Soft Magnetic Composite
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Solution Overview
Problem
Conventional electric motors with two-dimensional flux flow stator cores face limitations in maximizing power density and efficiency due to restricted magnetic flux directions, requiring complex and costly machining processes for precise component fabrication.
Innovation Solution
The development of a three-dimensional flux electric motor using a spray-formed isotropic soft-magnetic composite material for the stator, allowing magnetic flux flow in axial, radial, and circumferential directions, and employing a spray-forming process to produce stator components in near-net shape, reducing the need for extensive machining and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional two-dimensional flux flow stator cores are used, then the magnetic flux flow is restricted to two directions, but the power density and efficiency are limited
Solution Approach 1:
The patent transitions from conventional two-dimensional flux flow to three-dimensional flux flow by designing stator teeth with specific geometric features (trapezoidal shape with angled sides) that enable magnetic flux to flow in axial, radial, and circumferential directions simultaneously. This dimensional expansion increases power density without proportionally increasing device complexity.
Solution Approach 2:
The patent employs isotropic soft-magnetic composite materials for the stator core that possess magnetic properties in multiple directions. These composite materials enable the three-dimensional flux flow pattern by providing uniform magnetic permeability in all directions, resolving the contradiction between enhanced power density and device complexity.
2Manufacturing precision
If conventional machining processes are used for precise component fabrication, then manufacturing precision is achieved, but the process is complex and costly
Solution Approach 1:
The patent uses spray-forming technology to create near-net-shape stator components directly with the required geometric precision. By performing the shaping action during the forming process itself rather than through subsequent machining operations, the patent achieves manufacturing precision while dramatically reducing process complexity and cost.
Solution Approach 2:
The patent replaces conventional mechanical machining processes with a spray-forming process that deposits material in a controlled manner to create precise geometries. This substitution eliminates complex machining operations while maintaining or improving manufacturing precision through digital control of the spray deposition 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 three-dimensional flux design increases power density and efficiency while simplifying the manufacturing process by enabling the production of complex geometries without extensive post-machining, resulting in a more robust and efficient electric motor.
Implementation Method 1
allowing magnetic flux flow in axial, radial, and circumferential directions
Implementation Method 2
employing a spray-forming process to produce stator components in near-net shape
Data Source
AI summary
A method of making a stator includes providing a yoke, wherein the yoke comprises a spray-formed yoke; providing a tooth ring, wherein the tooth ring comprises a spray-formed tooth ring; separating portions of the tooth ring to form a plurality of teeth; arranging the separated teeth in a circular pattern, wherein each separated tooth is spaced from an adjacent tooth; inserting a coil over each separated tooth, wherein the coil includes two lead wires extending from a same face of each coil; locating the yoke onto the plurality of teeth; placing a housing onto the yoke; and connecting the coils to each other at the two lead wires extending from the same face of each coil.