Hybrid Stator for Axial Flux Motor Efficiency
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Solution Overview
Problem
Axial flux motors with sintered stators have reduced magnetic properties and mechanical integrity, leading to inefficiencies and increased production costs due to complex designs and manufacturing challenges.
Innovation Solution
A hybrid stator structure combining a sintered support made from powdered soft-magnetic material with a laminated core insert, allowing for complex magnetic field geometries and improved efficiency, while reducing manufacturing costs through a hybrid design that separates complex magnetic field creation from efficiency enhancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator is created using a sintering process with ferrite powder, then the desired magnetic field is formed comparatively precisely and production is inexpensive, but the electrical machine has reduced magnetic properties particularly in the low-frequency range, reducing efficiency
Solution Approach 1:
The stator combines two different materials with complementary properties: ferrite powder for cost-effective manufacturing and precise magnetic field formation, and electrical steel strips for superior magnetic properties and efficiency. This composite structure allows the sintered ferrite base to provide geometric precision while the inserted electrical steel components enhance magnetic performance, particularly in the low-frequency range.
2Ease of manufacture
If the stator is created using a sintering process, then production is comparatively inexpensive, but the mechanical integrity of the stator is comparatively low
Solution Approach 1:
The sintered ferrite base structure provides cost-effective manufacturing and precise magnetic field geometry, while the inserted electrical steel components with superior mechanical strength are bonded to the base using adhesive material. This composite construction enhances the overall mechanical integrity of the stator while maintaining the cost advantages of the sintering process.
3Loss of energy
If the stator is wound from strip strips of electrical steel in a spiral shape, then magnetic properties and efficiency are improved, but custom-made tape strips are required with increased production complexity and cost-intensive post-processing
Solution Approach 1:
The stator is divided into two separate components: a sintered ferrite base structure that provides the geometric framework and magnetic field formation, and separate electrical steel strip inserts that provide superior magnetic properties. This segmentation allows each component to be manufactured using optimized processes (sintering for the base, standard steel strip fabrication for inserts) and then assembled, reducing overall production complexity compared to creating a single custom-wound spiral structure.
4Loss of energy
If the stator is wound from strip strips of electrical steel, then magnetic properties are improved, but manufacturing tolerances are difficult to achieve due to play during rolling
Solution Approach 1:
The sintered ferrite base structure is manufactured first with precisely formed recesses that define the exact geometric framework and magnetic field geometry. These recesses are created with high precision during the sintering process. The electrical steel strip inserts are then manufactured separately using standard processes and subsequently bonded into the pre-formed recesses. This preliminary action of creating precise recesses beforehand eliminates the tolerance accumulation problems that occur during sequential rolling and assembly operations.
Solution Approach 2:
The sintered ferrite base structure acts as an intermediary that provides precisely formed recesses as a reference framework. These recesses serve as precision guides that accommodate the electrical steel strip inserts, ensuring accurate positioning and alignment. The adhesive material bonds the inserts to the base within these precision-redefined boundaries, achieving tight manufacturing tolerances without requiring the entire stator to be custom-wound with accumulated precision.
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 hybrid stator structure enhances magnetic efficiency and mechanical robustness, reduces manufacturing costs, and minimizes cogging torque, enabling the production of compact, high-performance axial flux motors with improved performance and reduced production complexities.
Implementation Method 1
The stator has a sintered support structure made from a powdered, soft-magnetic material. The material is particularly preferably a composite and has, for example, a ferrite powder or consists of this.
Implementation Method 2
The insert includes a laminated core that is created, for example, from a number of laminated core stacks, in each case made up of a number of individual laminations that are stacked on top of one another in the radial direction
Implementation Method 3
The stator also includes an insert bonded to the support structure. For example, the insert is attached to the support structure, for example by means of an adhesive.
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The invention relates to an electric machine (4), in particular an axial flux motor, with a rotor (8) rotatably mounted about a machine axis (2), and with a stator (12). The stator (12) has a sintered support structure (16) and an insert (18) connected thereto, which at least partially forms a pole shoe (52) and comprises a laminated core (40). The invention further relates to a stator (12) of an electric machine (4).