Laminated Core Joint Geometry for Rounder, Rigid Rotary Machines
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Solution Overview
Problem
Conventional laminated cores for rotary electric machines suffer from shape variation and instability in the angle formed by core pieces, leading to low roundness and rigidity against external forces due to arc-shaped end surfaces and varying connection positions.
Innovation Solution
A laminated core design featuring first and second core members with back yokes and magnetic pole teeth, where the projecting ends and recessed ends are aligned to form a stable annular shape, with the contact surfaces positioned in a plane including the center axis, enhancing the rigidity and roundness by equalizing forces between core pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If arc-shaped end surfaces are used for connection portions, then the core pieces can be connected rotatably to form an annular shape, but shape variation occurs in manufacturing and the angle between adjacent core pieces becomes unstable
Solution Approach 1:
The connection portions utilize arc-shaped surfaces that allow rotational movement while maintaining consistent angular relationships. The arc shape provides a curved contact surface that enables controlled rotation between core pieces while the geometry ensures stable angle formation between adjacent pieces in the annular configuration.
Solution Approach 2:
The connection portions are designed with asymmetric geometry where the arc-shaped surfaces have specific radius and positioning that differ from simple cylindrical joints. This asymmetric design ensures that while rotation is permitted, the angular relationship between adjacent core pieces remains stable and consistent, preventing shape variation during manufacturing and assembly.
2Ease of manufacture
If connection portions are positioned at varying locations on core pieces, then manufacturing flexibility is improved, but the roundness of the laminated core decreases
Solution Approach 1:
The connection portions are segmented into standardized locations on each core piece, with specific arc-shaped surfaces positioned at predetermined locations. This segmentation allows manufacturing flexibility while ensuring that when core pieces are assembled, the connection portions align consistently to maintain the roundness of the overall laminated core structure.
Solution Approach 2:
The design specifies particular geometric parameters for the connection portions, including arc radius, position relative to core piece dimensions, and orientation. By controlling these parameters, the invention achieves both manufacturing flexibility and consistent roundness in the final annular configuration.
3Device complexity
If core pieces are arranged with unstable angles between adjacent pieces, then assembly is simplified, but the rigidity of the laminated core against external force becomes low
Solution Approach 1:
The arc-shaped connection surfaces provide a curved interface that naturally guides the angular relationship between adjacent core pieces. This curved geometry ensures stable angle formation while simplifying assembly, as the arc shape allows core pieces to self-align during assembly. The consistent angular relationships resulting from the arc geometry provide the rigidity needed to resist external forces.
Solution Approach 2:
Multiple core pieces are combined through their connection portions to form a unified annular structure. The arc-shaped connection surfaces ensure that when assembled, the core pieces maintain stable angular relationships, creating a rigid overall structure that can resist external forces while keeping the assembly process relatively simple.
Data Source
AI summary
When a laminated core is formed in an annular shape, a radially inner part of a contact surface formed by a projecting end of a first core piece and a recessed end of another first core piece that are adjacent in a circumferential direction, and a radially inner part of a contact surface formed by a projecting end of a second core piece and a recessed end of another second core piece that are adjacent in the circumferential direction, are positioned in a plane including a center axis of the annular laminated core.