Amorphous Stator Using Powder-Molded Split Cores
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Solution Overview
Problem
Conventional electric motors face challenges with high core losses and manufacturing complexities due to the use of Si—Fe alloys, especially at high speeds, and amorphous metal materials are difficult to mold into complex shapes, leading to increased costs and inefficiencies.
Innovation Solution
The use of amorphous alloy powder compressed and molded into unit split cores, assembled with bobbins to form a simple structure, which reduces core losses and enables efficient permeability and packing density, allowing for high-speed and high-power motor operation with improved magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If Si-Fe alloys are used in high-speed electric motors, then the motor can operate at high speeds, but core losses increase excessively causing heating problems
Solution Approach 1:
The patent changes the material parameters by replacing conventional Si-Fe alloys with amorphous alloy powder, which has different magnetic properties including lower core loss and higher resistivity, enabling high-speed operation without excessive heating
Solution Approach 2:
The patent uses composite amorphous alloy powder materials with specific composition ratios (Fe-Si-B-Al-C system) to achieve optimal balance between magnetic performance and loss reduction for high-speed motor applications
2Loss of energy
If amorphous metal is used to replace conventional alloys, then core losses are reduced, but manufacturing complexity and costs increase due to difficulty in molding complex shapes
Solution Approach 1:
The patent divides the stator core into multiple unit split cores that can be independently molded from amorphous alloy powder, then assembled together, simplifying the molding process while maintaining low core loss benefits
Solution Approach 2:
The patent replaces conventional mechanical stamping and punching processes with compression molding of amorphous alloy powder, which can form complex three-dimensional shapes more easily and with less material waste
3Reliability
If amorphous metal ribbons are used, then magnetic performance is improved, but the material becomes brittle after annealing making it difficult to process
Solution Approach 1:
The patent changes the physical state of amorphous metal from ribbon form to powder form, which eliminates the brittleness issue after annealing while preserving the superior magnetic properties, and allows for easier processing and molding
Solution Approach 2:
The patent applies different treatments to amorphous alloy powder versus ribbon to optimize each form's properties, using compression molding for powder to achieve both good magnetic performance and processability
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
This approach minimizes core losses, enhances permeability, and simplifies the manufacturing process, resulting in more efficient and cost-effective high-power, high-speed electric motors with reduced size and weight.
Implementation Method 1
amorphous alloy powder is compressed and molded into a number of unit split cores, to then be assembled with bobbins, and to thus be easily molded into a core of a complex shape, and a core loss is minimized by using the amorphous alloy powder
Implementation Method 2
The present invention relates to an amorphous stator and an electric motor using the amorphous stator, and more specifically, to an amorphous stator for use in a high-power, high-speed electric motor, in which amorphous alloy powder is compressed and molded
Data Source
AI summary
Provided is an amorphous stator for use in a high-power, high-speed electric motor, and an electric motor using the amorphous stator, in which amorphous alloy powder is compressed and molded into a number of unit split cores, to then be assembled with bobbins, and to thus be easily molded into a core of a complex shape, and a core loss is minimized by using the amorphous alloy powder, to thus promote improvement of an efficiency of the motor. The electric motor includes: a stator in which a coil is wound on bobbins respectively formed in a number of unit split cores, and the number of unit split cores are assembled in an annular form by an integral or split bobbin; and a rotor that is rotated by an interaction with the stator, wherein the unit split cores are molded with mixed powder made of plate-shaped amorphous alloy powder and spherical soft magnetic powder.