Axial Gap Motor Dust Core Layout for Low Torque Ripple
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Solution Overview
Problem
The existing axial gap-type rotary electric machines face challenges in productivity and energy efficiency due to the separate fabrication and assembly of yokes and teeth, leading to variations in tooth protrusion heights, increased electromagnetic and mechanical energy losses, and noise from torque ripples.
Innovation Solution
The use of a dust core with integrally formed yokes and teeth, where the powder feeding machine ensures symmetrical filling, reducing tooth height variations and enabling equal intertooth distances, thereby minimizing torque ripples and enhancing energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If yokes and teeth are fabricated separately and assembled, then manufacturing flexibility is improved, but manufacturing precision deteriorates due to variations in tooth protrusion heights
Solution Approach 1:
The patent merges the yoke and teeth into a single integrally formed dust core component. The yoke and teeth are simultaneously formed from magnetic powder in one die cavity during the sintering process, eliminating the need for separate fabrication and assembly operations. This integral structure ensures consistent tooth protrusion heights and eliminates assembly errors, directly resolving the contradiction between manufacturing flexibility and manufacturing precision.
2Ease of operation
If yokes and teeth are assembled separately, then ease of assembly is improved, but productivity deteriorates due to additional assembly steps
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated process. The yoke and teeth are formed simultaneously in one die cavity during the sintering process, eliminating separate assembly steps. This reduces manufacturing complexity and improves productivity while maintaining ease of operation through the simplified single-step process.
Solution Approach 2:
The die cavity is pre-designed with the complete three-dimensional structure of both the yoke and teeth in their final positions. The magnetic powder is fed and sintered in this pre-configured die, so the components are formed in their final assembled state without requiring subsequent assembly operations, thereby improving productivity.
3Ease of manufacture
If separate yoke and teeth assembly is used, then ease of manufacture is improved, but energy efficiency deteriorates due to increased electromagnetic losses
Solution Approach 1:
The integral dust core structure eliminates air gaps and misalignments between separately assembled yoke and teeth components. This creates continuous magnetic flux paths with reduced magnetic reluctance and minimized eddy current losses, directly improving energy efficiency while the ease of manufacture is maintained through the simplified single-step sintering process.
4Ease of manufacture
If separate yoke and teeth assembly is used, then ease of manufacture is improved, but noise levels increase due to torque ripples
Solution Approach 1:
The integral dust core structure ensures precise geometric relationships between yoke and teeth with consistent tooth protrusion heights. This eliminates variations in air gaps and magnetic flux distribution that cause torque ripples and associated noise, while the ease of manufacture is preserved through the single-step sintering process that forms both components simultaneously.
Data Source
AI summary
Provided is an axial gap-type rotary electric machine in which a first stator, a second stator, and a rotor are arranged in a direction of a rotary shaft of the rotor. The first stator includes a first coil and a first core. The second stator includes a second coil and a second core. The first core includes an annular first yoke, a plurality of first teeth, and a first mark indicating a reference position in a circumferential direction of the first yoke. The second core includes an annular second yoke, a plurality of second teeth, and a second mark indicating a reference position in a circumferential direction of the second yoke.