Axial-Gap Motor Stator Tooth Assembly for Magnetic Flux Flow
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Solution Overview
Problem
Existing axial-gap-dynamoelectric machines face challenges in enhancing magnetic flux density and efficient magnetic flux flow due to the fragility of pressed powder iron core teeth and the need for precise assembly with laminated steel base yokes, which hinders magnetic flux circulation and complicates assembly processes.
Innovation Solution
The configuration includes a rotor with field magnets and a stator with pressed powder teeth and resin bobbins, where the teeth have a trapezoidal shape with larger outer-end portions and smaller inner-end portions, allowing efficient magnetic flux flow and improved assembly by reducing friction and gaps between teeth and base yokes, using positioning protrusions and holes for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the teeth are made of pressed powder iron core and inserted into the base yoke, then the magnetic flux density can be enhanced and the teeth can be formed in any shape, but the teeth are fragile and shaving occurs during assembly which reduces assemblability
Solution Approach 1:
A resin layer is provided between the pressed powder iron core teeth and the laminated steel base yoke before assembly. This resin layer acts as a cushioning material that prevents direct contact and friction between the fragile teeth and the base yoke during insertion, thereby preventing shaving and reducing assembly difficulty while maintaining magnetic flux density enhancement.
2Ease of operation
If a gap is formed between the teeth and the base yoke to prevent shaving, then the assemblability is improved, but the magnetic flux flow from the teeth to the base yoke is hindered
Solution Approach 1:
A resin layer is introduced as an intermediary material between the teeth and the base yoke. This resin layer fills the gap that would otherwise hinder magnetic flux flow, providing a continuous magnetic path while simultaneously preventing direct contact that causes shaving. The resin acts as a mediator that resolves the contradiction by maintaining both assemblability and magnetic flux flow efficiency.
3Ease of operation
If the teeth are carefully handled during assembly to prevent shaving, then the assemblability is improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The resin layer is provided beforehand between the teeth and the base yoke, creating a protective cushioning effect. This eliminates the need for careful handling during assembly operations, as the resin automatically prevents shaving. The assembly process becomes simpler and faster because the protective function is built into the structure rather than requiring meticulous manual handling.
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 magnetic flux density and flow efficiency while simplifying the assembly of teeth to the base yoke, reducing friction and maintaining magnetic flux circulation, thus improving the overall performance and assembly of the axial-gap-dynamoelectric machine.
Implementation Method 1
the resin layer between the pressed powder iron core teeth and the laminated steel base yoke reduces friction between the teeth and the base yoke
Implementation Method 2
an axial-gap-dynamoelectric machine comprising: a rotor rotatable about a rotation axis, the rotor including a plurality of magnets arranged around the rotation axis; a stator, aligned with the rotor in an axial direction of the stator, such that the rotation axis of the rotor is in an axial direction of the stator
Data Source
AI summary
An axial-gap-dynamoelectric machine includes resin bobbins having positioning protrusions, and a stator core including a base yoke having a plurality of tooth holes and positioning holes. In each tooth hole, a circumferential length of a tooth-hole-radial-direction-outer-end surface is larger than a circumferential length of a tooth-hole-radial-direction-inner-end surface. Each of the plurality of teeth has a columnar shape in which a circumferential length of a tooth-upper surface is larger than a circumferential length of a tooth-bottom surface. The positioning protrusions are inserted in the positioning holes, and press the teeth against the base yoke inward in the radial direction such that the tooth-bottom surface is brought into contact with the tooth-hole-radial-direction-inner-end surface and the tooth-oblique surface is brought into contact with the tooth-hole-circumferential-direction-end surface.