Axial Gap Motor Stator Core Positioning
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Solution Overview
Problem
Existing axial gap rotating electrical machines face challenges in accurately positioning stator cores and simplifying the manufacturing process, leading to increased cogging torque, vibration, noise, and reduced mechanical strength, which affects the performance of the machines.
Innovation Solution
The design features a housing frame body with cylindrical central and circumferential spaces, a rotatable shaft, cores and coils arranged in specific positions, and a rotor yoke with magnets, along with a nonmagnetic case that integrates the housing frame body, reducing the number of assembly parts and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin-molding is used to form the stator, then the manufacturing process is simplified, but the mechanical strength of the joints is reduced and stator cores may be displaced during rotation
Solution Approach 1:
The patent combines multiple components (housing frame body, support members, and positioning structures) into a single integrated housing frame body. This eliminates the need for separate resin-molding processes and assembly steps, while maintaining strong mechanical joints through direct structural integration rather than adhesive bonding.
Solution Approach 2:
The housing frame body is segmented into functional regions (first space for shaft, multiple second spaces for cores) that are built-in during manufacturing. This allows precise positioning of stator cores without requiring post-assembly adjustments or weak adhesive bonds, as the positioning structures are inherently part of the housing structure.
2Manufacturing precision
If positioning jigs and molding dies are used to accurately position cores, then positioning precision is improved, but the manufacturing process complexity increases
Solution Approach 1:
The housing frame body is manufactured with built-in positioning structures (first space for shaft, multiple second spaces for cores) that pre-establish accurate positions before core installation. This eliminates the need for separate positioning jigs and molding dies, as the positioning function is integrated into the housing structure itself, reducing manufacturing process complexity while maintaining precision.
3Manufacturing precision
If support members are provided to hold stator cores, then core positioning is improved, but the area opposed to magnets is reduced and flux linkage is decreased
Solution Approach 1:
The patent merges the positioning function into the housing frame body structure itself, rather than using separate support members. The first space and multiple second spaces are integral parts of the housing that provide positioning while minimizing interference with the magnetic field. This eliminates the need for additional support structures that would block flux paths between magnets and cores.
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 configuration enhances the accuracy of stator core positioning, reduces manufacturing time and costs, and improves the motor's performance by minimizing cogging torque and noise, while allowing for the selection of materials based on cost, insulation, or strength requirements.
Implementation Method 1
a pair of rotor having two circular disks provided on the respective opposite surfaces thereof with permanent magnets and a shaft coupling the circular disks together, located in the centers thereof; a stator made up of multiple cores and coils to which the permanent magnets are opposed with a gap in between
Data Source
AI summary
When an axial gap rotating electrical machine is assembled, stator cores are accurately positioned and a manufacturing process therefor is simplified. The axial gap rotating electrical machine comprises: a housing frame body having a first space in the cylindrical central part thereof and multiple second spaces located in the circumferential direction which have the same distances from the center; a shaft rotatably provided in the first space in the housing frame body; a core placed in each of the second spaces in the housing frame body and a coil arranged around the core; a rotor yoke fixed on the shaft, extended in the direction of the circumference thereof, and having multiple magnets arranged in circumferential positions confronting the cores; and a case having a hole for the shaft and housing the housing frame body and the rotor yoke.