Adjustable Stator Core Spacing for Increased Wire Area
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Solution Overview
Problem
Conventional stators face limitations in increasing the area occupied by wire due to the need for a new winding machine and complex manufacturing processes, which affect manufacturing efficiency and magnetic resistance.
Innovation Solution
A stator design with a diffusion angle regulator and connector system that allows for adjustable spacing between split cores, enabling the use of existing winding machines and reducing manufacturing complexity while maintaining magnetic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional winding machine is used to wind wire around teeth, then the wire area can be increased, but a predetermined space must be secured between adjacent teeth for the nozzle to pass, which limits further wire area increase
Solution Approach 1:
The stator core is divided into multiple split cores that can be arranged linearly during winding, allowing the nozzle to access teeth without requiring large circumferential spaces. After winding, the split cores are connected to form the complete annular core.
2Quantity of substance
If split cores are linearly connected to increase wire area, then more wires can be wound, but a new winding machine must be introduced because the conventional winding machine cannot handle linear arrangement
Solution Approach 1:
The split cores are designed to be movable relative to each other, allowing them to be arranged linearly during winding and then connected to form the annular shape. This dynamic reconfiguration enables the use of conventional winding machines while achieving increased wire area.
3Ease of manufacture
If split cores are connected by twisting to insert pin portion into elongated hole, then the connected split cores can be joined, but a dedicated jig is required and workability is low
Solution Approach 1:
A connector is introduced as an intermediary component to join the split cores. The connector includes a sliding groove and slider that enable simple linear insertion and connection, eliminating the need for complex twisting operations and dedicated jigs.
4Adaptability or versatility
If protrusion and elongated hole are formed on steel plates to connect split cores, then spacing distance can be adjusted, but manufacturing cost increases due to complex mold and magnetic resistance increases due to elongated holes
Solution Approach 1:
The connector serves as an intermediary that provides spacing adjustment functionality without requiring complex modifications to the steel plates themselves. The sliding groove and slider mechanism in the connector enables adjustable spacing while maintaining simple, standard manufacturing processes for the steel plates.
Data Source
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AI summary
A stator and a motor include a plurality of split cores disposed in an annular shape and a connector configured to connect the plurality of split cores to allow a circumferential spacing distance between the split cores to be changed, wherein a diameter of the stator is changed by changing the spacing distance between the split cores in a state in which the plurality of split cores disposed in an annular shape by the connector.