Axial Flux Motor Stator Assembly for Precise Iron Core Positioning
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Solution Overview
Problem
Existing axial flux motors face challenges in conveniently positioning segmented iron cores relative to the circuit substrate when the axial size of the iron core is smaller than the coil, leading to deviations in motor performance and cogging torque.
Innovation Solution
The axial flux motor incorporates holding seats made of insulating material that cover segmented iron cores from both axial and circumferential directions, with slot holes on the circuit substrate for positioning, and features such as accommodating chambers and elastic snap-fits to facilitate precise alignment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the axial size of the segmented iron core is made smaller than the axial size of the coil, then the motor structure becomes more compact, but it becomes difficult to position the segmented iron cores relative to the circuit substrate, leading to performance deviation and cogging torque
Solution Approach 1:
The patent introduces holding seats as intermediary components made of insulating material. These holding seats have accommodating chambers that receive the segmented iron cores and protrude beyond the coil axially, providing a reliable positioning interface with the circuit substrate through slot holes. This mediator solves the positioning problem created by the reduced iron core axial size.
Solution Approach 2:
The patent extends the positioning function into the axial dimension by designing holding seats that protrude axially beyond the coil. This allows the positioning reference to be established in a different dimensional space (axial protrusion) rather than relying solely on the iron core's axial size, thereby solving the positioning accuracy issue.
2Manufacturing precision
If holding seats are introduced to position the segmented iron cores, then positioning accuracy improves, but the device complexity increases due to additional components
Solution Approach 1:
The holding seats serve multiple functions simultaneously: they provide positioning through slot hole engagement, electrical insulation between the iron core and coil, mechanical support for the iron core, and coil winding guidance. By consolidating these functions into a single component, the patent reduces overall device complexity despite adding the holding seat.
Solution Approach 2:
The patent merges the positioning function, insulation function, and support function into the holding seat component. This consolidation approach, while adding a component, eliminates the need for separate positioning structures, insulation layers, and support elements, thereby managing device complexity effectively.
Data Source
AI summary
An axial flux motor includes a rotor assembly and a stator assembly. The rotor assembly has magnets. The stator assembly has a circuit substrate, segmented iron cores, and a coil. The circuit substrate extends radially. The segmented iron cores are supported on the circuit substrate to be opposite to the magnet in the axial direction. Segmented iron cores arranged in the circumferential direction. A coil is sleeved on a segmented iron core. Holding seats of an insulating material correspond respectively to the segmented iron cores. A holding seat abuts with and covers a segmented iron core from both axial sides and the circumferential direction, and is used for winding the coil. The circuit substrate has slot holes. A slot hole is used for embedding and positioning a portion of a holding seat that protrudes more towards one axial side than the coil.