Axial Air Gap Motor Laminated Core Width Variation
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Solution Overview
Problem
The axial air gap type electric motor faces productivity losses due to thickness variations in laminated iron cores, leading to buckling or dropping issues during assembly, requiring frequent adjustments in the number of laminated layers to maintain core shape and size, which decreases productivity.
Innovation Solution
The motor design includes a laminated iron core with continuously laminated metal plate-like members, where widths increase radially from the shaft center, allowing for adjustable layer numbers to maintain fixed dimensions and secure outside diameters, facilitating precise assembly and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of laminated layers is increased or decreased to compensate for plate thickness deviation, then the laminated layer thickness can be adjusted, but the shape of the laminated iron core becomes different and productivity decreases
Solution Approach 1:
The patent applies parameter changes by modifying the width parameter of the metal plate-like members in the radial direction. Instead of changing the number of laminated layers to adjust thickness, the invention changes the width of individual plates to compensate for thickness variations, thereby maintaining both manufacturing precision and productivity
Solution Approach 2:
The patent implements preliminary action by pre-designing the width variation pattern of metal plate-like members before lamination. The widths are predetermined to increase from the rotating shaft center outward, allowing automatic compensation for plate thickness deviation without requiring post-assembly adjustments or frequent counting changes
2Reliability
If the laminated layer thickness becomes large, then the iron core cannot be correctly inserted due to buckling, but if the thickness becomes small, the iron core drops from the bobbin
Solution Approach 1:
The patent applies local quality by creating non-uniform width distribution across different radial positions of the metal plate-like members. The plates near the rotating shaft center have smaller widths while outer plates have larger widths, providing localized structural characteristics that prevent both buckling and dropping during assembly
3Manufacturing precision
If the cutting dimension and number of laminated layers are controlled by measuring plate thickness always, then manufacturing precision can be maintained, but productivity is significantly decreased
Solution Approach 1:
The patent eliminates the need for continuous plate thickness measurement by changing the control parameter from number of layers to width of individual plates. The width variation pattern is predetermined and does not require real-time measurement or adjustment, thereby maintaining manufacturing precision while significantly improving productivity
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 approach enables easy adjustment of laminated dimensions to match thickness variations, ensuring accurate insertion and maintaining motor performance by stabilizing the laminated core shape and reducing productivity losses.
Implementation Method 1
The iron core is a laminated iron core having a substantially trapezoidal-shaped cross-section formed by laminating metal plate-like members in the radial direction of the rotating shaft
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(c)
Figure 3~4
AI summary
The purpose of the present invention is to efficiently cope with the plate thickness deviation of a laminated iron core in an axial air gap type electric motor. An axial air gap type electric motor comprises: a stator formed by arranging stator cores (6) around a rotating shaft (4) in a ring shape, said stator cores (6) each including a laminated iron core (8) that is a prismatic body formed by laminating metal plate-like members in a radial direction of the rotating shaft, a tubular bobbin (7) that has an inner diameter into which the laminated iron core is inserted, and a coil (9) that is wound on the extension of the outer diameter of the laminated iron core; and at least one rotor (3) plane-facing the rotating shaft direction end section of the stator with a predetermined air gap interposed therebetween. The laminated iron core includes: a portion (core member (10b)) formed by continuously laminating the metal plate-like members, the widths of which increase in a rotational direction of the rotating shaft from the rotating shaft center toward a radial direction; and a portion (core member (10a)) formed by continuously laminating the metal plate-like members, the widths of which are substantially equal.