Iron Core Member with V-Shaped End Joint Portions
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Solution Overview
Problem
Conventional rotating electrical machines face challenges in size reduction, weight reduction, high space factor, and productivity due to issues such as reduced space factor, excessive rigidity of coils, and complex mechanisms required for coil insertion, which hinder size and weight reduction and increase production costs.
Innovation Solution
An iron core member with stacked ring-shaped divided yoke and tooth portions, allowing for seamless integration of coils without deformation, reducing the number of components, and enabling the use of larger wire diameters, which improves space factor and productivity by simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If divided cores are inserted from outer circumference side into stator coil, then number of components is reduced and productivity is improved, but dead space must be provided in slot to avoid interference with tooth portion, reducing space factor and output
Solution Approach 1:
Instead of inserting tooth portions into the coil from the outer circumference side as in conventional technology, this patent inserts the coil into the stator core from the inner circumference side. This inversion of the insertion direction eliminates the need for dead space in slots, avoiding the trade-off between productivity improvement and space factor reduction.
2Ease of operation
If coil is inserted into core, then coil insertion property is improved and number of components is reduced, but wire diameter must be 2 mm or shorter to maintain flexibility, reducing space factor and hindering size reduction
Solution Approach 1:
The patent reverses the conventional insertion approach by inserting the coil into the stator core from the inner circumference side rather than inserting the core into the coil from the outer circumference. This allows use of wires with diameter of 2 mm or longer while maintaining good insertion properties, thereby improving space factor and enabling size reduction of the rotating electrical machine.
3Ease of operation
If tooth portions are inserted individually into coil, then insertion is possible, but coil deformation occurs and regularity is disordered, significantly deteriorating insertion property and requiring complex synchronous insertion mechanism
Solution Approach 1:
Instead of inserting tooth portions individually or synchronously into the coil, the patent inserts the entire coil into the stator core from the inner circumference side. This single-step inversion approach avoids coil deformation and maintains regularity without requiring complex synchronous insertion mechanisms.
Solution Approach 2:
The patent combines multiple tooth portions and the coil into a single integrated assembly by inserting the coil into the stator core as one operation. This merging approach eliminates the need for separate insertion operations for each tooth portion, simplifying the mechanism while maintaining insertion property.
Data Source
AI summary
An iron core member has: first divided yoke portions; second divided yoke portions alternately arranged with the first divided yoke portions; a first tooth portion extending from one circumferential end of each first divided yoke portion, a second tooth portion extending from the other circumferential end; a third tooth portion extending from one circumferential end of the second divided yoke portion on the second tooth portion side, and a fourth tooth portion extending from the other circumferential end. A tooth end portion of the first tooth portion and a tooth end portion of the adjacent fourth tooth portion are integrally joined at a first tooth end joint portion, and a tooth end portion of the second tooth portion and a tooth end portion of the adjacent third tooth portion are integrally joined at a second tooth end joint portion, thereby providing one continuous sheet of the core member.