Friction Welded Stator Carrier Segmentation

Solution Overview

Problem

Conventional cast stator carriers in electric motors suffer from porosity issues, leading to product failure, and have limited design flexibility due to inflexible molds and high machining costs.

Innovation Solution

A method involving forming stamped components and joining them via friction or laser welding, allowing for a stator carrier composed of aluminum or aluminum alloy components, with simultaneous or paired welding of axial end faces to form a stator carrier.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional casting method is used to make stator carrier, then production cost is reduced, but porosity issues occur leading to product failure

Engineering Contradiction:

Improveproduct failure rateVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The stator carrier is divided into multiple separate components (first end component, second end component, and intermediate component) that are manufactured independently and then joined together. This segmentation allows each component to be produced using optimized stamping processes without the porosity issues inherent in conventional casting, while the final assembly achieves the required structural integrity and reliability.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If cast stator carrier is used, then initial production cost is low, but machining costs increase and design flexibility is limited

Engineering Contradiction:

Improvedesign flexibilityVSAvoidmachining cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By segmenting the stator carrier into separate stampable components, the design can be more easily adapted and modified. Each component can be independently designed and manufactured, allowing for greater design flexibility and easier implementation of design changes without requiring expensive retooling of entire casting molds.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces conventional casting and subsequent machining operations with a stamping and welding process. Stamping directly produces the final component shapes without requiring extensive post-machining, thereby reducing machining costs and enabling more complex designs to be manufactured more efficiently.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If cast stator carrier is used, then mold adaptability is limited, but production efficiency is maintained

Engineering Contradiction:

Improvemold adaptabilityVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The stator carrier is divided into multiple separate components (first end component, second end component, and intermediate component) that are manufactured independently and then joined together. This segmentation allows each component to be produced using optimized stamping processes without the porosity issues inherent in conventional casting, while the final assembly achieves the required structural integrity and reliability.

Inventive Principle:

Principle #1Segmentation

4Strength

If friction welding is used to join components, then joint strength is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveweld joint strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention replaces conventional casting and subsequent machining operations with a stamping and welding process. Stamping directly produces the final component shapes without requiring extensive post-machining, thereby reducing machining costs and enabling more complex designs to be manufactured more efficiently.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method reduces porosity-related failures and lowers production costs while enabling design flexibility and efficient machining of the stator carrier.

Implementation Method 1

Joining the axial end faces of the first and second end components to respective opposite axial end faces of the intermediate component includes joining with welding process. The welding process can include at least one of friction welding or laser welding.

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Implementation Method 2

The welding process can include at least one of friction welding or laser welding.

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS20250226733A1Friction welded stator carrier

Publication Date: 2025.07.10 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A method of making a stator carrier for an electric motor includes forming a first end component, forming a second end component, forming an intermediate component, and joining axial end faces of the first and second end components to respective opposite axial end faces of the intermediate component. Joining the axial end faces is done by friction or laser welding to form welds or weld regions between the components.