Axial Gap Stator Asymmetric Core Winding for Resin Filling
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Solution Overview
Problem
The voids between coils in axial gap type rotating electric machines vary in shape, leading to unsatisfactory resin filling during molding, which decreases the reliability and increases the size and cost of the machine, impairing productivity.
Innovation Solution
The configuration involves arranging core members with different numbers of coil winding layers around a rotary shaft, where the first core member has more winding layers on one side and the second core member has fewer, ensuring a uniform void for resin filling, and alternating their arrangement to maintain size reduction and improve reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the void shape is irregular due to varying coil quantities, then resin filling becomes unsatisfactory, but making the void larger to ensure flow passage increases machine size and cost
Solution Approach 1:
The invention changes the geometric parameters of the void by arranging core members with different coil winding layer configurations. Specifically, it alternates between core members with more winding layers on one side and those with fewer layers, transforming the irregular void shape into a uniform, controlled geometry that ensures proper resin filling without increasing overall machine size
Solution Approach 2:
The invention applies asymmetry by creating core members with non-uniform coil winding distributions - some core members have more winding layers on one side while adjacent core members have fewer layers. This asymmetric arrangement strategically shapes the void spaces to maintain uniformity across the stator assembly, resolving the contradiction between reliable resin filling and compact machine size
2Reliability
If core members are extended in the rotary shaft direction to reduce coil overlapping, then void size increases for better resin flow, but machine size and cost increase
Solution Approach 1:
Instead of extending core members in the rotary shaft direction (one dimension), the invention addresses resin flow issues by manipulating the radial and axial arrangement of coils through asymmetric winding layer configurations. This multi-dimensional approach creates uniform void spaces without increasing the overall length of core members, thereby maintaining compact machine dimensions while ensuring adequate resin flow passages
3Manufacturing precision
If core members are extended to ensure void size, then resin filling improves, but productivity decreases due to increased size and cost
Solution Approach 1:
The invention optimizes manufacturing efficiency by changing the geometric parameters of void spaces through asymmetric coil arrangement rather than increasing core member dimensions. This parameter optimization ensures complete resin filling for manufacturing quality while avoiding the increased material costs and production complexity that would reduce productivity
Solution Approach 2:
The invention applies local quality by creating specific void characteristics at different locations through the asymmetric arrangement of coil winding layers. Each interface between core members with different winding configurations produces locally optimized void geometry that ensures uniform resin filling across the entire stator assembly, achieving manufacturing precision without overall size increase
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 ensures sufficient resin filling, reducing the size of the electric machine while enhancing its reliability and productivity by maintaining a uniform void and efficient resin flow.
Implementation Method 1
the plurality of core members arranged annularly are integrally molded by means of resin molding to obtain the stator
Data Source
AI summary
The moldability of the stator of an axial gap type rotating electric machine improved. The axial gap type rotating electric machine has: a stator comprising core members disposed about a rotating shaft in a ring shape with a predetermined space from adjacent core members, said core members each having a core around which a coil is wound, the number of the turns of the coil being less on the outer perimeter side than on the inner perimeter side, the core members being molded with mold material; and a rotor facing an end surface of the core in the shaft direction through a predetermined gap. The core members comprise: a first core member in which the number of coil winding layers on one side in the shaft direction is larger than the number of winding layers on the other side; and a second core member in which the number of coil winding layers on one side in the shaft direction is less than the number of winding layers on the other side. In the stator, the first and second core members are alternately disposed, with the coil on the side where the number of the winding layers of the first core member is larger and the coil on the side where the number of the winding layers of the second core member is smaller opposed to each other.