Air Core Stator with Non-Magnetic Support
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Solution Overview
Problem
Existing stator designs for electrical machines face challenges in effectively supporting stator coils within an air gap configuration while minimizing the air gap height and ensuring proper separation and fixation of coils without direct attachment to magnetic back iron sections.
Innovation Solution
The stator configuration includes non-magnetic support frame sections and axial coil supports that are not directly fixed to the magnetic back iron, with coil support stiffeners between the support teeth, allowing stator coils to be securely positioned within slots defined by these components, which contact the magnetic back iron sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If stator coils are directly fixed to magnetic back iron sections, then structural support is simplified, but air gap height cannot be minimized and magnetic interference occurs
Solution Approach 1:
Non-magnetic axial coil supports and non-magnetic support frame sections are introduced as intermediary components between the stator coils and magnetic back iron sections. These intermediaries prevent direct contact, allowing the air gap to be minimized while avoiding magnetic interference and providing indirect structural support.
Solution Approach 2:
The support structure is divided into multiple non-magnetic components including axial coil supports, support frame sections, and coil support stiffeners. This segmentation allows each component to perform specific functions (coil positioning, structural support, stiffness reinforcement) while maintaining the air gap and preventing magnetic interference.
2Manufacturing precision
If non-magnetic support structures are introduced to minimize air gap, then coil positioning is improved, but structural stiffness is reduced
Solution Approach 1:
The support structure uses composite construction with non-magnetic materials (such as fiberglass-reinforced plastics or carbon fiber composites) that provide both the required electrical isolation from magnetic fields and sufficient mechanical stiffness to support the stator coils accurately.
Solution Approach 2:
Coil support stiffeners are positioned in three-dimensional space between support teeth of adjacent non-magnetic support frame sections, creating a spatial framework that enhances structural stiffness without interfering with the air gap or coil positioning in the critical radial dimension.
3Stability of the object's composition
If coil support stiffeners are added between support teeth, then structural integrity is enhanced, but device complexity increases
Solution Approach 1:
Multiple functions are combined into integrated non-magnetic components. The axial coil supports both position the coils radially and provide structural reinforcement, while the support frame sections simultaneously support the coils and provide mounting points for stiffeners, reducing the need for separate dedicated components.
Data Source
AI summary
Stator for use in an electrical machine. A non-magnetic support frame section and a non-magnetic axial coil support are used to provide an air gap stator configuration. The present stators provide an air gap winding configuration that facilitates the fixing of stator coils in the air gap. The stator coils are located near the surface of the magnetic back iron and are separated from adjacent coils by non-magnetic structure.