Helical Lamination Ring Casing for Low-Eddy-Current Motor Stators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing ring cylindrical casings for rotating electromechanical apparatuses are complex and wasteful, requiring multiple manufacturing steps and expensive machinery, and they often suffer from significant eddy current issues due to direct contact between windings.
Innovation Solution
A ring cylindrical casing with a helical lamination stack formed from a magnetically permeable material, where the material is wound in a helical shape with insulation coating to reduce eddy currents and minimize material waste, featuring a support cylinder for mechanical and thermal connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional punching or stamping methods are used to produce lamination stacks, then the desired shape can be obtained, but the manufacturing process becomes complex and requires expensive machinery
Solution Approach 1:
The patent changes the manufacturing approach from discrete punching/stamping operations to a continuous helical winding process. The strip material is wound around a mandrel in a continuous operation, transforming the manufacturing parameters from batch processing to continuous production, thereby simplifying the overall process while maintaining shape accuracy
Solution Approach 2:
The patent segments the manufacturing process into two simple steps: first forming the helical shape by winding, then cutting to length. This segmentation eliminates the need for complex punching and stamping operations, reducing device complexity while preserving the ability to achieve desired shapes
2Manufacturing precision
If conventional punching or stamping methods are used to produce lamination stacks, then the desired shape can be obtained, but multiple manufacturing steps and expensive machinery are required
Solution Approach 1:
The patent transforms the manufacturing method from multiple discrete steps (punching, stamping, laser cutting) to a single continuous helical winding operation. This parameter change in the manufacturing process significantly improves ease of manufacture while maintaining the ability to produce accurate shapes through controlled winding tension and mandrel geometry
Solution Approach 2:
The patent merges multiple manufacturing operations (forming, shaping, and initial positioning) into a single helical winding operation. The winding process simultaneously creates the helical shape, positions the layers, and prepares the structure for final cutting, thereby simplifying the overall manufacturing process
3Loss of energy
If insulation coating is applied to the strip, then eddy currents are reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The insulation coating is applied to the strip material before the helical winding process begins. This preliminary action ensures that eddy current paths are interrupted from the start, reducing energy losses without adding complexity to the winding operation itself. The coating is applied once during material preparation rather than during assembly
Solution Approach 2:
The patent incorporates the insulation coating as an integral parameter of the strip material itself, changing the material properties rather than adding a separate manufacturing step. This approach reduces eddy currents by modifying the electrical properties of the material while keeping the manufacturing process simple
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 helical lamination stack significantly reduces manufacturing steps, minimizes material waste, and effectively suppresses eddy currents, enhancing the efficiency and performance of the electromechanical apparatus by providing a solid, smooth surface for reduced electromagnetic interference.
Implementation Method 1
The strip comprises two main surfaces and two side surfaces, wherein at least one of the two main surfaces comprises an insulation coating
Implementation Method 2
The helical lamination stack is formed out of a helically wound strip of magnetically permeable material
Implementation Method 3
The ring cylindrical casing (11) further comprises a support cylinder (120), wherein a permanent connection is formed between the helical lamination stack and the support cylinder (120)
Data Source
AI summary
A ring cylindrical casing and a method for manufacturing the ring cylindrical casing of a rotating electromechanical apparatus and a rotating electromechanical apparatus including the ring cylindrical casing, wherein the ring cylindrical casing has a substantially cylindrical inner surface and/or substantially cylindrical outer surface, wherein the ring cylindrical casing includes a helical lamination stack of a helically wound strip of magnetically permeable material, having multiple turns, wherein the strip includes two main surfaces and two side surfaces, wherein at least one of the main surfaces includes an insulation coating.