Additive Manufactured Solenoid Stator Core with Radially Aligned Slots
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Solution Overview
Problem
Conventional solenoid actuated fuel injectors face challenges with fast acting solenoids due to eddy currents caused by magnetic fields, which require complex manufacturing processes and increased costs for stator cores with multiple slots.
Innovation Solution
A one-piece solenoid stator core is designed using additive manufacturing, featuring radially aligned outer and inner slots that reduce eddy currents without the need for precise assembly, and can be filled with electrically insulating material to enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If multiple slots are provided in the stator core to reduce eddy currents, then the response time and fuel delivery efficiency are improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple slot features into a single monolithic stator core component manufactured via additive manufacturing. Instead of creating separate slot pieces that require assembly, the additive process directly forms multiple radial slots (first slot, second slot, third slot, fourth slot) as integrated features of the core structure, eliminating assembly complexity while maintaining the eddy current reduction benefits of multiple slots
Solution Approach 2:
The patent changes the manufacturing parameter from conventional subtractive or assembly-based methods to additive manufacturing. This parameter change enables the direct formation of complex multi-slot geometries in a single build process, resolving the contradiction between achieving multiple slots for speed improvement and avoiding manufacturing complexity
2Productivity
If multiple slots are provided in the stator core to reduce eddy currents, then the fuel delivery efficiency is improved, but the assembly precision requirements increase
Solution Approach 1:
The patent combines multiple slot features into a single monolithic stator core component manufactured via additive manufacturing. Instead of creating separate slot pieces that require assembly, the additive process directly forms multiple radial slots (first slot, second slot, third slot, fourth slot) as integrated features of the core structure, eliminating assembly precision requirements while maintaining the eddy current reduction benefits of multiple slots
Solution Approach 2:
The additive manufacturing process itself performs the slot formation function that would otherwise require separate manufacturing and assembly operations. The process inherently creates the precise slot geometries and positions without requiring external assembly operations, making the system self-sufficient and eliminating assembly precision constraints
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 solution simplifies the manufacturing process, reduces eddy currents, and improves the efficiency of fuel delivery by using a single, integrated component that can be easily assembled, thereby enhancing the speed and control of solenoid actuation.
Implementation Method 1
the outer wall segments, the inner wall segments and the lower wall are formed using an additive manufacturing process such that the outer wall segments and the inner wall segments are formed onto the lower wall
Implementation Method 2
the outer slots and the inner slots are filled with an electrically insulating material
Data Source
AI summary
A one-piece solenoid stator core is provided, comprising: a plurality of outer wall segments; a plurality of inner wall segments; and a lower wall extending between the plurality of outer wall segments and the plurality of inner wall segments; wherein a plurality of outer slots is defined between the plurality of outer wall segments and a plurality of inner slots is defined between the plurality of inner wall segments, each of the outer slots being radially aligned with an inner slot relative to a central axis of the stator core.