Amorphous Alloy Laminated Core Clamping Design
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Solution Overview
Problem
Existing laminated cores for electromagnetic devices, such as electric motors, face issues with secure fixation of amorphous alloy plates, leading to potential cracking and reduced space factor due to resin layers, which affects mechanical torque and iron loss.
Innovation Solution
A laminated core design featuring amorphous alloy plates stacked directly with clamping plates and holding members that maintain a predetermined space, eliminating the need for resin layers and ensuring secure fixation without cracking, while maximizing the space factor and reducing iron loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin layers are used to bond amorphous alloy plates, then the plates are fixed together, but the space factor is reduced and iron loss increases
Solution Approach 1:
The invention removes the resin layers from between the amorphous alloy plates, extracting the harmful element that reduced space factor and increased iron loss. The plates are directly contacted and bonded through the clamping plates without intermediate resin layers, thus improving the space factor and reducing eddy current loss while maintaining fixation reliability.
2Ease of manufacture
If windings are wound around the laminated core to hold plates together, then the core is assembled, but the amorphous alloy plates are not securely fixed in the stacking direction under mechanical torque
Solution Approach 1:
The invention introduces separate clamping plates that segment the structure into distinct functional components: the laminated body of amorphous alloy plates and the clamping plates that secure them. This segmentation allows the clamping plates to specifically address the mechanical stability issue in the stacking direction through direct contact and clamping force, while the windings can focus on their electromagnetic function.
Solution Approach 2:
The clamping plates apply counteracting clamping force in the stacking direction to counterbalance the mechanical torque and separation forces that act on the amorphous alloy plates. This counter force ensures the plates remain securely fixed together under operational mechanical loads, preventing delamination and maintaining structural integrity.
3Stability of the object's composition
If amorphous alloy plates are clamped between support plates, then the core structure is formed, but cracks are generated around welded parts when welding from lateral side
Solution Approach 1:
The invention introduces holding members as intermediary elements between the clamping plates and the amorphous alloy plates. These holding members serve as mediators that apply clamping force through the end surfaces of the plates rather than through lateral welding, eliminating the thermal stress and crack generation associated with lateral welding while maintaining secure structural formation.
Data Source
AI summary
A laminated core includes a laminated body, clamping plates and holding members. The laminated body includes a plurality of amorphous alloy plates, which are stacked one after another in a stacking direction such that each adjacent two of the plurality of amorphous alloy plates directly contact with each other. The clamping plates contact opposed end surfaces, respectively, of the laminated body in the stacking direction. A thickness of each of the first and second clamping plates in the stacking direction is larger than that of each of the plurality of amorphous alloy plates. Each holding member contacts with the clamping plates and maintains a predetermined space between the clamping plates while the laminated body is clamped between the clamping plates.