Dual-Phase Stator Lamination for Leakage Reactance Reduction
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Solution Overview
Problem
High-speed electric machines experience mechanical losses due to fluid or gas churn in the rotor-stator gap and face manufacturing complexities and increased leakage reactance with existing stator lamination designs, limiting their power capability and power factor.
Innovation Solution
A stator lamination made from dual-phase magnetic material, which can transition between different magnetic states, allowing for a smoother surface without wedges and reduced leakage reactance, enabling higher speed, efficiency, and improved power factor with reduced volume, mass, and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If slot wedges are installed in the slot closures to close the slot opening, then the stator surface becomes smoother, but the leakage reactance increases
Solution Approach 1:
The patent removes the slot wedges from the slot closure design, allowing the slot opening to remain open rather than closed. This extraction of the wedge component eliminates the source of increased leakage reactance while maintaining an acceptable stator surface profile for high-speed operation.
Solution Approach 2:
The patent applies different magnetic permeability properties to different regions of the stator lamination. By using dual-phase magnetic material with varying permeability characteristics in specific areas, the design optimizes the balance between surface smoothness and leakage reactance without requiring physical wedges.
2Shape
If the slot opening is closed with magnetic lamination material to provide a smoother stator bore, then the surface quality improves, but the leakage reactance increases compared with open slot design
Solution Approach 1:
The patent extracts the slot closure material from the slot opening region, maintaining an open slot design. This removal prevents the increase in leakage reactance that would result from closing the slot with magnetic material, while the stator bore achieves sufficient smoothness through alternative means.
3Adaptability or versatility
If separate components are used to form stator teeth with concentrated windings, then the manufacturing flexibility improves, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the stator teeth into a single monolithic core structure rather than using separate components. This consolidation simplifies the manufacturing process by reducing the number of parts and assembly steps, while still allowing for concentrated winding configurations through appropriate design of the integrated structure.
Solution Approach 2:
The monolithic stator core design serves multiple functions simultaneously: it provides the structural framework, defines the slot geometry, and supports the concentrated windings. This multi-functional approach reduces manufacturing complexity while maintaining the flexibility needed for different winding configurations.
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 dual-phase magnetic material design reduces leakage reactance and mechanical losses, enhancing the power capability and power factor of electric machines while simplifying manufacturing and reducing costs.
Implementation Method 1
a dual magnetic phase material, the dual magnetic phase material being having a magnetic property in a first state and a magnetic property in a second state, wherein the magnetic property in the second state is different than the first state
Data Source
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AI summary
A stator lamination (10) for an electric machine has a circular lamination (12) with an annular bore (14) therethrough; winding slots (20) therethrough; and, slot closures (30) disposed adjacent to the winding slots (20). The stator lamination (10) is formed of a dual magnetic phase material, such that the magnetic property of the lamination (10) can have a first state and a magnetic property in a second state, wherein the second state is different than the first state. The slot closures regions (30) are treated so as to transition to the second state. A method of manufacturing an electric machine component is also disclosed.