Flexible PCB Stator Winding for Slotless AC Motor Assembly
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Solution Overview
Problem
The structure of existing motor stators, particularly in small motors, is complex and difficult to process and assemble due to the presence of stator slots and armature windings.
Innovation Solution
A motor stator design featuring a stator yoke with a cavity and a flexible circuit board that includes conductive layers with coils, which are attached to the stator yoke, generating a radial magnetic field and interacting with the rotor magnetic field to produce electromagnetic torque, eliminating the need for stator slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stator core with stator slots and armature windings is used, then the motor structure is suitable for large-size motors, but the structure becomes difficult to process and assemble in small motors
Solution Approach 1:
The patent extracts and removes the traditional stator slots from the stator core structure. Instead of having separate slots for armature windings, the design uses a smooth stator core with windings directly embedded or attached to the core surface, eliminating the complex slot structure while maintaining the motor's electromagnetic functionality.
Solution Approach 2:
The patent merges the stator core and armature winding structures into a more integrated design. The winding structure is combined with the stator core in a way that eliminates the need for separate slot structures, making the overall stator assembly simpler and easier to manufacture, particularly for small motors.
2Power
If stator slots and armature windings are included in the motor stator structure, then the motor can generate electromagnetic torque, but the structure becomes difficult to process and assemble in small motors
Solution Approach 1:
The patent extracts the slot structure from the stator design, removing the complexity associated with creating and assembling slots while preserving the essential function of generating electromagnetic torque through alternative winding arrangements on a smooth core.
Solution Approach 2:
The patent changes the geometric parameters of the stator structure by eliminating slots and using a smooth core design. This parameter change simplifies manufacturing processes while maintaining the electromagnetic torque generation capability through modified winding configurations that adapt to the smooth core surface.
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 design reduces structural volume, simplifies processing and assembly, and enhances the convenience of manufacturing motor stators by attaching the flexible circuit board to the stator yoke, improving magnetic field strength and efficiency.
Implementation Method 1
The current passes through the coil, generating a radial magnetic field perpendicular to the stator yoke in the air gap of the motor, and interacts with the rotor magnetic field to generate the electromagnetic torque required for the operation of the motor
Data Source
AI summary
Disclosed are a motor stator and an AC motor. The motor stator includes a stator yoke and a stator winding. A cavity is provided inside the stator yoke. The stator winding includes a flexible circuit board formed by winding and having a same shape as the cavity. The flexible circuit board includes a plurality of groups of coils, the plurality of groups of coils are provided at intervals along a circumference of the stator yoke and are electrically connected to the terminal. The flexible circuit board is attached to an inner wall of the stator yoke. The current passes through the coil, generating a radial magnetic field perpendicular to the stator yoke in the air gap of the motor, and interacts with the rotor magnetic field to generate the electromagnetic torque required for the operation of the motor.