Continuous Stator Core and Winding Frame for AC Motors
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Solution Overview
Problem
Conventional stator cores in air conditioner outdoor units are difficult to manufacture due to the use of split cores, which increase manufacturing cost and time, and complicate the coil connection process.
Innovation Solution
A stator core configuration featuring continuous stator core bodies connected by coupling slots and projections, with continuous winding frames that guide coils and facilitate PCB coupling, reducing manufacturing complexity and time while minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If split cores are used in conventional stator cores, then the stator core can be assembled from separate parts, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent merges multiple separate split cores into a single continuous stator core body. The continuous stator core eliminates the need for assembling multiple separate parts, thereby simplifying the manufacturing process while maintaining the necessary structural complexity for motor operation.
2Productivity
If split cores are coupled together to form round stator core, then the stator core can be constructed from manageable parts, but manufacturing time and cost increase
Solution Approach 1:
The continuous stator core body combines what were previously separate split core parts into one integrated component. This merging eliminates the time-consuming assembly process of coupling multiple parts together, thereby improving manufacturing efficiency and reducing production time.
3Ease of operation
If coils are wound on separate winding frames, then each coil can be independently manufactured, but the connection process becomes difficult and time-consuming
Solution Approach 1:
The patent merges multiple separate winding frames into a single continuous winding frame that is integrated with the continuous stator core. This allows coils to be wound continuously across what were previously separate sections, greatly simplifying the connection process and reducing the complexity of organizing and connecting multiple separate coil assemblies.
Data Source
AI summary
The present invention relates to a stator core including at least two or more stator core-continuous bodies each formed by coupling at least two or more unit cores to each other, each unit core consisting of a tooth portion having a coupling slot and a coupling projection formed along both ends thereof and connected to adjacent unit core by means of a connection portion formed at each of both end portions of the tooth portion, wherein the at least two or more stator core-continuous bodies are fitting-connected to each other by means of the coupling slots formed at one side ends thereof and the coupling projections formed at the other side ends thereof to form the stator core having a round shape.