Bent Stator Core Structure With Overlapped Bending Gaps
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Solution Overview
Problem
Existing stator cores in outer rotor motors face challenges in reducing magnetic resistance in the gaps between bending portions and improving rigidity, which affects motor performance, noise, and vibration.
Innovation Solution
A stator core design where a plurality of straight core pieces are stacked and then bent, featuring alternating first and second core pieces with specifically positioned bending portions and an overlapping portion to facilitate easy bending and reduce magnetic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If core pieces are bent after stacking to form annular stator core, then electrical steel usage is reduced and manufacturing efficiency is improved, but magnetic resistance increases due to gaps at bending portions
Solution Approach 1:
The core piece is divided into multiple segments (first core piece, second core piece, third core piece) with bending portions at different positions. When stacked, these segments form an annular structure where the gaps from individual bends are distributed and overlapped, reducing the overall magnetic resistance compared to a single large bend.
Solution Approach 2:
Multiple core pieces with bending portions are stacked and nested together to form the final annular stator core. The bending portions of different core pieces are positioned at different locations, and when stacked, they create overlapping regions that reduce the effective gap size and magnetic resistance.
2Productivity
If multiple core pieces are stacked and bent, then manufacturing efficiency is improved, but rigidity of the stator core deteriorates
Solution Approach 1:
The stator core is segmented into multiple core pieces that are stacked together. This segmentation allows each piece to be manufactured separately with standard bending processes, improving manufacturing efficiency while the stacked structure maintains overall rigidity through the combination of multiple pieces.
Solution Approach 2:
Multiple core pieces are merged together through stacking to form the complete annular stator core. The combination of multiple pieces creates a structure that maintains rigidity comparable to a single-piece core while benefiting from the manufacturing efficiency of segmented production.
3Ease of manufacture
If bending portions are formed at same position of all core pieces, then manufacturing process is simplified, but magnetic resistance increases due to concentrated gaps
Solution Approach 1:
The bending portions of different core pieces are positioned asymmetrically at different locations around the annular structure. This asymmetric positioning distributes the gaps throughout the structure rather than concentrating them at one location, reducing the overall magnetic resistance while maintaining manufacturing simplicity.
Solution Approach 2:
Instead of positioning all bending portions at the same radial position, the invention distributes them at different angular positions around the annular core. This dimensional distribution in the angular direction reduces the concentration of gaps and thereby reduces magnetic resistance.
Data Source
AI summary
A stator core formed by stacking and then bending a plurality of straight core pieces having a plurality of bending portions is provided, wherein the core pieces each include a plurality of first core pieces and a plurality of second core pieces stacked between the plurality of first core pieces, and the bending portions each include a connecting portion formed at the same position of the plurality of first core pieces and the plurality of second core pieces when the plurality of first core pieces and the plurality of second core pieces are stacked, a first bending portion formed by cutting the plurality of first core pieces and formed on one side of the connecting portion with respect to the center of the connecting portion, and a second bending portion formed by cutting the plurality of second core pieces and formed on the other side of the connecting portion with respect to the center of the connecting portion, and wherein based on the plurality of first core pieces and the plurality of second core pieces being stacked, the first bending portion is entirely covered by the second core pieces, and the second bending portion is entirely covered by the first core pieces.