Flexible Stator Lamination for Rotary Actuator Air Gap Elimination
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Solution Overview
Problem
Existing rotary electromagnetic actuators face inefficiencies due to undesired air gaps between the stator lamination stack and the outer enclosure, which reduce torque output and increase reluctance, and current methods for eliminating these gaps are complex, costly, and often incomplete.
Innovation Solution
A flexible stator lamination design that can deform to fit within an outer enclosure, allowing for a precise line-to-line fit and eliminating air gaps by configuring each lamination to flex into a shape that conforms to the enclosure's inner diameter, forming a press fit without the need for additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the outer enclosure is heated to expand its inner diameter for pressing the stator lamination into the enclosure, then the stator lamination can be fitted into the enclosure, but the process becomes complex and costly
Solution Approach 1:
The patent changes the physical state of the stator lamination by making it flexible rather than rigid. The stator lamination is designed to be inserted in a flexible state and then allowed to return to its original shape, creating a press fit without requiring thermal expansion or complex assembly equipment. This resolves the contradiction by achieving precise fitting through material property changes rather than complex process steps.
2Stability of the object's composition
If adhesive is used to connect the outer enclosure and stator laminations, then unwanted rotation or axial translation is prevented, but adhesive functions as an undesirable air gap and increases reluctance
Solution Approach 1:
The patent removes the adhesive layer from the assembly by using a flexible stator lamination that creates a direct mechanical press fit against the outer enclosure. The flexibility allows the lamination to conform to the enclosure inner surface, eliminating the need for adhesive while maintaining positional stability and avoiding the creation of air gaps that would increase magnetic reluctance.
3Manufacturing precision
If the stator lamination is made rigid for structural stability, then it maintains its shape, but it cannot deform to fit within the outer enclosure and eliminate air gaps
Solution Approach 1:
The patent introduces dynamic flexibility to the stator lamination, allowing it to deform during assembly by bending into a curved configuration for insertion, then return to its original flat shape once positioned. This dynamic behavior enables the lamination to adapt to the outer enclosure geometry and eliminate air gaps while maintaining structural integrity through its elastic properties rather than rigid constraints.
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 solution enhances torque efficiency by eliminating air gaps and ensuring a precise magnetic flux path, while being cost-effective and ensuring a secure, sealed connection between the stator laminations and the outer enclosure.
Implementation Method 1
A flexible stator lamination is designed to deform when pressure is applied thereto, thus allowing the stator lamination to be positioned within the outer enclosure
Implementation Method 2
Each of the stator laminations is configured to flex into a shape so as to be positionable within the outer enclosure and substantially conform to the inner diameter
Data Source
AI summary
A rotary actuator includes an outer enclosure having an inner diameter surrounding a hollow interior. A stack of stator laminations, each having a stator diameter greater than the inner diameter of the outer enclosure when in an unflexed state, are also included in the rotary actuator. Each of the stator laminations is configured to flex into a shape so as to be positionable within the outer enclosure and substantially conform to the inner diameter. The stator lamination thus forms a line-to-line fit with at least a portion of the outer enclosure to form an interface having a desirable reluctance.