Folded Stator Core Unfolding for Reduced Magnetic Resistance
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Solution Overview
Problem
Compact electric rotating machines with stators composed of divided cores face challenges in achieving high output power due to magnetic resistance and increased iron loss from eddy currents, limiting their ability to generate sufficient power in compact spaces.
Innovation Solution
A stator design featuring a stator core with slots and windings, incorporating core members with radially extending tooth portions that unfold to accommodate in-slot portions, reducing magnetic resistance and minimizing iron loss through the use of amorphous metal and electromagnetic steel plates, along with a specific winding configuration and assembly method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator core is constituted by a plurality of divided cores, then the ease of manufacture is improved, but the magnetic resistance increases
Solution Approach 1:
A magnetic connection structure (yoke portions) is introduced as an intermediary element to connect the divided cores. This mediator reduces the magnetic resistance at the connection interfaces while maintaining the manufacturing advantages of divided cores, effectively resolving the contradiction between ease of manufacture and magnetic performance.
2Reliability
If lap portions are provided to reduce magnetic resistance, then the magnetic resistance is reduced, but eddy currents occur causing iron loss to increase
Solution Approach 1:
The harmful lap portions that cause eddy currents are completely removed from the design. Instead of trying to reduce their negative effects, the invention extracts eliminates this source of energy loss entirely while maintaining low magnetic resistance through the magnetic connection structure between divided cores.
3Volume of stationary object
If the electric rotating machine is made compact, then the volume is reduced, but the output power becomes insufficient
Solution Approach 1:
The stator core is segmented into multiple divided cores connected by magnetic connection structures. This segmentation allows for optimized space utilization and reduced overall volume while maintaining effective magnetic pathways, enabling compact design without sacrificing output power capability.
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 design achieves a compact and high-output electric rotating machine with reduced magnetic resistance and minimized iron loss, enhancing performance and power generation capabilities while maintaining structural rigidity.
Implementation Method 1
the core member being configured such that each of the first tooth portions folded toward the core back portion is capable of unfolding to extend between a corresponding adjacent two of the in-slot portions
Implementation Method 2
a stator winding constituted by conductive wires wound on the slots the stator winding including in-slot portions accommodated in the slots and turn portions each connecting each adjacent two of the in-slot portions outside of the slots
Data Source
AI summary
A method of manufacturing an electric rotating machine having a stator that includes a stator core having slots formed at an inner periphery thereof, and a stator winding constituted by conductive wires wound on the slots. The stator winding includes in-slot portions accommodated in the slots and turn portions each connecting each adjacent two of the in-slot portions outside the slots. The stator core includes a core member having at least three tooth portions extending in a radial direction of the stator core and a core back portion integrally connecting the tooth portions at a radially end side thereof. The core member is configured such that each of the first tooth portions folded toward the core back portion is capable of unfolding to extend between a corresponding adjacent two of the in-slot portions when the core member is at a predetermined axial position with respect to the stator winding.