Linear Compressor Stator Assembly for Magnetic Loss and Vibration Control
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Solution Overview
Problem
Linear compressors face inefficiencies due to magnetic saturation and increased volume issues in stators with coils, leading to reduced compression efficiency and motor stability, along with loose lamination fixation during vibration, affecting safety and service life.
Innovation Solution
The design incorporates smaller second stator pieces within larger gaps between first stator pieces, with filling pieces to enhance magnetic conductivity and reduce magnetic loss, and a fixing method using protrusions and through holes to securely attach stator laminations, improving assembly precision and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the radial length of stator lamination group is increased, then the magnetic field intensity is improved, but the gap between adjacent stator lamination groups and outer circumference of inner stator increases
Solution Approach 1:
The patent applies nesting by placing filling pieces within the existing gaps between stator lamination groups and the outer circumference of the inner stator. These filling pieces are nested into the gap space, effectively utilizing the available volume to increase the radial length of the magnetic path without increasing the overall stator volume, thereby improving magnetic field intensity while minimizing gap volume.
2Manufacturing precision
If stator laminations are fixed tightly, then the assembly precision is improved, but the vibration during operation causes loose fixation
Solution Approach 1:
The patent applies preliminary action by pre-forming protrusions on the stator laminations before assembly. These protrusions are designed to fit into corresponding recesses in the fixing component, creating a pre-configured mechanical interlock that maintains tight fixation during operation despite vibration, thus preserving both assembly precision and fixation stability.
3Reliability
If the volume of stator with coil is increased, then the magnetic saturation is avoided, but the overall volume of motor increases
Solution Approach 1:
The patent applies local quality by strategically placing filling pieces in specific locations where they provide maximum magnetic conductivity enhancement. The filling pieces are positioned in the gaps between stator lamination groups, locally improving the magnetic path quality without requiring a uniform increase in the entire stator volume, thus preventing magnetic saturation while maintaining compact motor dimensions.
4Strength
If protrusions are formed on stator laminations, then the fixation strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the stator structure into modular components with protrusions formed on individual stator laminations. These protrusions are created as separate features that can be manufactured using standard stamping or punching processes, allowing for easy integration into the assembly process without significantly increasing overall manufacturing complexity, while providing strong mechanical interlocking with the fixing component.
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 the motor's driving force, stability, and efficiency while reducing volume and preventing magnetic saturation, leading to improved performance and reliability of linear compressors.
Implementation Method 1
When the coil 17 is electrified, the magnetic field intensity of the magnetic field formed by the inner stator 14 and the outer stator 15 is changed. Under the magnetic field force, the rotor 16 moves back and forth (in a left-right direction in FIG. 1) along an axis thereof.
Implementation Method 2
a filling piece provided in at least one of the spaces surrounded by the two adjacent first stator pieces and the second stator pieces
Data Source
AI summary
In one aspect of the present invention, a stator of a linear compressor comprises first stator pieces that are circumferentially and sequentially arranged about an axial direction and are radially disposed, second stator pieces that are provided between outer parts of the adjacent first stator pieces, and an outer side, away from a motor axis, of the second stator pieces assembled at an outer circumference of the stator. The stator can reduce the magnetic losses of the stator caused by the gap, and improve the efficiency of the motor. It can also improve the performance, stability, durability and reliability of the linear compressor. It can also reduce the bulk of the linear compressor.