Axial Gap Stator Core Assembly With Off-Center Teeth for Higher Torque
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Solution Overview
Problem
Existing axial gap type rotating electrical machines face challenges in achieving high torque and manufacturability, particularly in the assembly and magnetic flux passage between the stator teeth and yoke.
Innovation Solution
A core design featuring an annular yoke with through-holes and columnar teeth, where the teeth are inserted off-center into the yoke, creating a small magnetic gap for enhanced torque and manufacturability, with specific configurations such as proximal regions and material compositions like pure iron or iron alloys to optimize magnetic flux and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the teeth are inserted off-center in the through-holes, then magnetic flux passage is improved and torque is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The core is divided into separate components (yoke and teeth) that are manufactured independently and then assembled. The teeth are inserted into the through-holes of the yoke in an off-center position, creating a controlled magnetic gap that enhances torque while allowing independent manufacturing of each component.
Solution Approach 2:
The off-center insertion creates a non-uniform magnetic gap distribution, with smaller gaps in certain regions and larger gaps in others. This local variation in gap size optimizes magnetic flux passage in critical areas while maintaining overall torque enhancement, and the design accommodates natural manufacturing variations.
2Productivity
If the yoke and teeth are composed of separate powder compacts, then assembly efficiency is improved, but structural complexity increases
Solution Approach 1:
The core structure is segmented into a yoke component and multiple teeth components, each manufactured as separate powder compacts. This segmentation enables parallel manufacturing and simplified assembly, where the teeth are inserted into the through-holes of the yoke, improving productivity while the modular design actually reduces overall structural complexity.
Solution Approach 2:
The teeth are inserted into the through-holes of the yoke, creating a nested configuration where the teeth are positioned within the structural framework of the yoke. This nesting approach simplifies the overall assembly process while maintaining the benefits of separate component manufacturing.
3Power
If small magnetic gaps are created by off-center insertion, then torque is enhanced, but magnetic flux passage uniformity decreases
Solution Approach 1:
The off-center insertion creates intentionally non-uniform magnetic gaps, with smaller gaps in regions where enhanced magnetic flux passage is critical for torque generation. This local optimization of gap size allows the design to achieve higher torque while the varied gap distribution actually improves overall magnetic flux utilization by directing flux through more efficient paths.
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
The design effectively inhibits torque reduction and enhances manufacturability by ensuring better magnetic flux passage and uniform tooth fixation, resulting in a high-torque axial gap type rotating electrical machine with improved assembly efficiency.
Implementation Method 1
creating a small magnetic gap for enhanced torque and manufacturability, with specific configurations such as proximal regions and material compositions like pure iron or iron alloys to optimize magnetic flux and assembly
Data Source
AI summary
A core used in an axial gap type rotating electrical machine includes an annular yoke having a plurality of through-holes disposed in a circumferential direction, and a plurality of columnar teeth disposed in the circumferential direction of the yoke, each of the plurality of columnar teeth including one end inserted into each of the plurality of through-holes. The yoke and each of the teeth are composed of a powder compact separate from each other, and the one end of each of the teeth is off-center in the through-hole.