Composite Stator Tooth Grooves to Cut Flux Leakage and Chipping
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Solution Overview
Problem
Rotating electrical machines using amorphous or nanocrystalline soft magnetic metals for stators face issues of chipping, cracking, magnetic saturation, and reduced torque due to clearance gaps, leading to reliability and efficiency concerns.
Innovation Solution
A stator design where a second iron core part made of amorphous or nanocrystalline soft magnetic metal is disposed in groove parts of a first iron core part made of electrical steel sheets, with groove shapes that narrow inward and closed ends, ensuring close contact and reducing magnetic flux leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the stator is made of amorphous or nanocrystalline soft magnetic metal, then magnetic permeability is improved, but toughness deteriorates causing chipping and cracking
Solution Approach 1:
The stator is divided into two distinct parts: a first iron core part made of electrical steel sheets and a second iron core part made of amorphous or nanocrystalline soft magnetic metal. This segmentation allows each part to contribute its advantageous properties - the electrical steel provides toughness and structural integrity, while the soft magnetic metal provides low magnetic loss and high permeability.
Solution Approach 2:
The invention creates a composite stator structure combining two different materials - electrical steel sheets and amorphous/nanocrystalline soft magnetic metal. This composite approach allows the stator to simultaneously exhibit the mechanical strength of electrical steel and the superior magnetic properties of soft magnetic metal, resolving the contradiction between toughness and magnetic performance.
2Loss of energy
If the stator is made of amorphous or nanocrystalline soft magnetic metal, then magnetic permeability is improved, but saturation magnetic flux density deteriorates
Solution Approach 1:
The stator is segmented into two functional zones: the first iron core part made of electrical steel sheets handles high magnetic flux density requirements, while the second iron core part made of soft magnetic metal optimizes for low magnetic loss and high permeability in regions where flux density is lower. This segmentation allows each material to operate in its optimal performance range.
Solution Approach 2:
Different materials are assigned to different locations within the stator based on local magnetic field requirements. The electrical steel sheets are positioned where high flux density is needed, while the soft magnetic metal is positioned where low loss and high permeability are prioritized, achieving local optimization of magnetic properties.
3Ease of manufacture
If clearance is provided for inserting the second iron core part, then ease of manufacture is improved, but magnetic flux leakage increases
Solution Approach 1:
Protrusions are pre-formed on the second iron core part and corresponding grooves are pre-formed on the first iron core part before assembly. These preliminary structural features guide the insertion process and ensure proper positioning, allowing tight magnetic coupling without requiring excessive clearance for alignment during assembly.
Solution Approach 2:
The protrusions and grooves create interlocking curved surfaces that facilitate smooth insertion while maintaining tight contact. The geometric design of these interlocking features allows the components to be inserted with minimal clearance while ensuring close magnetic coupling that prevents flux leakage.
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
The design enhances reliability and efficiency by preventing chipping, reducing magnetic saturation, and maintaining high torque, resulting in a more robust and efficient rotating electrical machine.
Implementation Method 1
since the amorphous soft magnetic metal or the nanocrystalline soft magnetic metal has high magnetic permeability but has low saturation magnetic flux density
Implementation Method 2
a first groove part formed in the tooth parts from an outer peripheral surface of each of the plurality of tooth parts, and the second iron core part is disposed in the first groove part
Data Source
AI summary
The stator for a rotating electrical machine includes an annular first iron core part, which is a stacked body including electrical steel plates, and second iron core part, which is a stacked body including an amorphous soft magnetic metal or a nanocrystalline soft magnetic metal, wherein: the annular first iron core part includes a plurality of tooth parts which protrude toward the inner circumferential side and around which a coil is wound, and first groove parts formed within each tooth part from an outer circumferential surface; and the second iron core parts are disposed in the first groove parts.