Hinged Stator Core for Wire Winding and Magnetic Circuit Integrity
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Solution Overview
Problem
Conventional stator cores are difficult to wind with wire, leading to material waste and reduced motor efficiency due to their circular structure, and existing solutions with individual iron cores still face disengagement issues during wire winding.
Innovation Solution
A hinged stator core composed of individual iron cores with a hinge and hinge slot structure, allowing axial connection and preventing disengagement, facilitating wire winding and forming a circular core with high mechanical strength through laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional entire-circle stator core is used, then the structure is simple and manufacturing is fast, but wire winding is difficult and material waste increases
Solution Approach 1:
The stator core is divided into multiple individual iron cores (typically 3-12 pieces) that can be separated and reassembled. Each iron core contains teeth and a yoke structure with hinge connections, allowing them to be disassembled into a linear arrangement for easy wire winding, then reassembled into the final circular stator core structure.
2Ease of operation
If individual iron cores are used without hinge connection, then wire winding is easier, but the iron cores may disengage during the winding process
Solution Approach 1:
The hinge connection structure provides dynamic characteristics: during wire winding, the individual iron cores can be arranged in a linear configuration for accessibility; after winding is complete, the hinge connections enable the iron cores to be assembled into the final circular stator core structure. The hinge allows controlled movement and positioning throughout the manufacturing process.
3Reliability
If individual iron cores are connected to form a circular stator core, then the magnetic circuit integrity is improved, but the wire winding process becomes more complex
Solution Approach 1:
The wire winding process is performed on individual iron cores or a linear arrangement of iron cores before final assembly into the circular stator core. This preliminary action simplifies the winding process by providing easier access to the core structure, and the hinge connections facilitate the subsequent assembly into the final circular configuration with proper magnetic circuit integrity.
Data Source
AI summary
The present invention discloses a hinged stator core. The hinged stator core consists of a plurality of individual iron cores each comprising teeth on an inner side and a yoke on an outer side; two adjacent individual iron cores are connected by a hinge structure comprising a hinge and a hinge slot fitted with the hinge, with both the hinge and the hinge slot being arranged on the yoke of the individual iron core; the hinge and the hinge slot are arranged on a side, which rotates about a rotor shaft clockwise and/or on a side, which rotates about a rotor shaft counterclockwise, of the yoke of the individual iron core; the hinge consists of a fitting segment fitted with the hinge slot and a connecting segment for connecting the fitting segment with the yoke; the fitting segment has a circular or segmental shape along a radial cross-section of the rotor shaft; the hinge slot has an arced shape along the radial cross-section of the rotor shaft; and both a center of a circle of the fitting segment of the hinge and a center of a circle of the hinge slot are in the circumference of a circle taking a center of the stator core as its center. The present invention has the advantages of convenient manufacturing and processing, more convenient wire winding, and high integrity of the magnetic circuit.