AFPM Stator Support Structure for Coil Cooling and Space Factor
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Solution Overview
Problem
Conventional AFPM motors face issues with reduced space factor and difficulty in cooling coils due to the presence of a T-shaped support member between stator cores, which impedes fluid flow and secure support.
Innovation Solution
A stator core support member with a novel structure, including a pair of first support portions, a second support portion with a greater width, and a third support portion, along with bobbins having elastic holes, to enhance space factor and cooling efficiency while securely supporting stator cores in a circumferential direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a T-shaped support member is used to secure stator cores, then the stator cores are securely supported, but the space factor is reduced and cooling efficiency deteriorates due to blocked fluid flow
Solution Approach 1:
The support member is divided into multiple modular components: a support ring, multiple support members with first and second support portions, and elastic bobbins. This segmentation allows each component to perform its specific function while maintaining overall structural stability and enabling fluid flow paths that were blocked by the conventional T-shaped design.
Solution Approach 2:
The elastic bobbins are extracted as separate elastic elements that can be inserted into grooves of the support members. This extraction allows the support structure to gain elastic deformation capability, enabling it to adapt to thermal expansion and contraction while maintaining secure support of stator cores without blocking cooling fluid flow.
2Productivity
If the stator core support structure is simplified to improve cooling flow, then cooling efficiency improves, but the security of stator core support may be compromised
Solution Approach 1:
The support members have different support portions with specific local functions: first support portions contact the stator cores at specific locations, while second support portions extend to engage with the support ring. This local differentiation ensures secure support at critical points while maintaining open pathways for cooling fluid flow in other areas.
Solution Approach 2:
The support members feature asymmetric geometry with first support portions positioned to contact stator cores and second support portions extending in different directions to engage the support ring. This asymmetric design provides stable support while creating asymmetric flow channels that facilitate efficient cooling fluid circulation.
3Stability of the object's composition
If elastic bobbins are introduced to enhance support adaptability, then support stability under thermal variation improves, but device complexity increases
Solution Approach 1:
The elastic bobbins are merged with the support member structure by inserting them into grooves of the support members. This merging integrates the elastic function directly into the support structure, allowing the system to adapt to thermal expansion and contraction of stator cores without requiring a completely separate adjustment mechanism, thereby limiting the increase in complexity.
Solution Approach 2:
The elastic bobbins provide self-adjusting support by deforming in response to thermal expansion and contraction of the stator cores. This self-service mechanism automatically compensates for thermal variations without requiring external control systems or complex adjustment mechanisms, maintaining simplicity while enhancing adaptability.
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
Improves space factor and cooling efficiency while securely supporting stator cores, preventing contact and potential short circuits, and facilitating effective fluid flow around the coils.
Implementation Method 1
each of the pair of bobbins may include an elastic hole formed in one side thereof. When each of the pair of bobbins is supported by the second support portion, the pair of bobbins may elastically support each of the plurality of stator cores as the elastic hole is deformed.
Data Source
AI summary
An embodiment stator for an axial flux permanent magnet (AFPM) motor includes a plurality of stator cores arranged in a circumferential direction, each stator core of the plurality of stator cores including a winding portion on which a coil is wound and end portions of a wedge shape on both sides of the winding portion, and a plurality of core support members, each core support member of the plurality of core support members including a pair of first support portions configured to support the end portions, a second support portion connecting a first end of a first one of the pair of first support portions to a first end of a second one of the pair of first support portions, and a third support portion connecting second ends of the pair of first support portions to each other.