Axial Gap Stator Core Through-Hole Fixation Without Flux Loss
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Solution Overview
Problem
Stator cores formed by magnetic powder cores face reliability issues when fixed to surrounding members, as adhesive-based fixation methods are not mechanically robust.
Innovation Solution
Incorporating through holes in the stator core made of compaction-molded soft magnetic powder with insulating films, allowing for secure mechanical fixation using bolts and nuts, and optimizing the placement and size of these holes to minimize interference with magnetic flux while ensuring structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive-based fixation method is used for stator core, then manufacturing simplicity is maintained, but fixation reliability deteriorates
Solution Approach 1:
The stator core is segmented by forming through-holes that pass through the magnetic powder core body, allowing mechanical fasteners (bolts, nuts, or rivets) to be inserted. This segmentation enables reliable mechanical fixation to the housing while maintaining the integrity of the magnetic powder core structure.
Solution Approach 2:
The through-holes act as intermediaries that connect the stator core to the housing via mechanical fasteners. These holes provide a pathway for bolts, nuts, or rivets to mechanically secure the stator core, replacing the inadequate adhesive-based fixation method with a robust mechanical connection system.
2Reliability
If through holes are added for mechanical fixation, then fixation reliability improves, but magnetic flux integrity deteriorates
Solution Approach 1:
The through-holes are strategically positioned in non-critical areas of the stator core where magnetic flux density is low. By carefully selecting hole locations and optimizing their dimensions, the design ensures that mechanical fixation is achieved while minimizing disruption to the magnetic flux paths in the high-density regions.
Solution Approach 2:
The magnetic powder core inherently has a porous microstructure due to its compaction molding process. The through-holes utilize and extend this porous characteristic, creating a controlled porosity that allows mechanical fastening while the insulating film coating on the magnetic powder particles maintains magnetic flux integrity through the porous structure.
3Reliability
If through holes are formed after compaction molding, then fixation capability improves, but manufacturing time increases
Solution Approach 1:
The through-holes are formed during the compaction molding process itself, before the magnetic powder core is completed and assembled. The mold includes pre-formed hole structures that are created as the magnetic powder is compacted, eliminating the need for subsequent drilling or punching operations and reducing overall manufacturing time.
Solution Approach 2:
The hole formation operation is merged with the compaction molding process. By integrating the through-hole creation into the primary forming operation, the patent eliminates separate manufacturing steps, thereby reducing total manufacturing time while ensuring the holes are precisely positioned and dimensioned.
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 method provides a reliable mechanical fixation of the stator core to surrounding members, maintains magnetic flux integrity, and reduces manufacturing costs and time by integrating through holes during compaction molding.
Implementation Method 1
a body portion formed by a compaction-molded body of soft magnetic powder whose surfaces are coated with insulating films
Implementation Method 2
surfaces are coated with insulating films
Data Source
AI summary
This stator core is a stator core for a rotating electric machine of an axial gap type and includes a body portion formed by a compaction-molded body of soft magnetic powder whose surfaces are coated with insulating films, wherein the body portion is provided with one or a plurality of through holes.