Maglev Motor Stator Coil Structure for High-Density Winding
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Solution Overview
Problem
Existing stator mechanisms for magnetic levitation motors fail to maximize coil density in a limited space, leading to issues such as poor contact between stator teeth and yoke, air gaps, and insufficient magnetic flux due to arbitrary winding designs.
Innovation Solution
A stator mechanism with a stator core and insulating framework featuring cambered and straight surfaces, allowing coils to be tightly attached and wound efficiently, minimizing space usage and preventing breakage or alignment issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the windings are made saturated to maximize coil density, then the coil density is improved, but the coil will cause poor contact between the stator teeth and the stator yoke and create air gaps, resulting in uneven magnetic flux
Solution Approach 1:
The patent applies curvature by designing the inner circumferential surface of the stator yoke and the outer surface of the stator teeth as cambered surfaces with matching radii of curvature. This curved geometry allows the coil to be tightly wound against the cambered surface while maintaining uniform contact between the stator teeth and stator yoke, eliminating air gaps and ensuring even magnetic flux distribution throughout the magnetic circuit.
2Volume of moving object
If the windings have small turns to reduce space occupation, then the space usage is improved, but it is impossible to obtain the ampere-turns required to generate a sufficient magnetic field
Solution Approach 1:
The patent utilizes the radial dimension by winding the coil in multiple layers around the cambered surface of the stator teeth. This multi-layer radial arrangement allows the coil to occupy minimal axial and tangential space while achieving the required number of turns through vertical stacking in the radial direction, thereby generating sufficient ampere-turns for a strong magnetic field without excessive space occupation.
3Quantity of substance
If the coil is tightly wound to maximize space utilization, then the coil density is improved, but the coil may break or have alignment issues
Solution Approach 1:
The cambered surface design provides a smooth, continuous curved path for the coil windings, which naturally guides the wire along the curvature and distributes mechanical stress evenly throughout the coil structure. This curved geometry prevents sharp bends and stress concentration points that would otherwise cause wire breakage or misalignment, thereby maintaining coil integrity while achieving high density.
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 design achieves a higher coil density and compact structure, reducing energy loss and increasing magnetic flux uniformity, thereby enhancing the magnetic levitation performance.
Implementation Method 1
A copper coil 212 is wound on the vertical portion to provide a radial electromagnetic force to the rotor 22 so as to levitate the rotor 22
Implementation Method 2
Both the stator tooth 211 and the rotor 22 are made of a magnetically conductive material
Data Source
AI summary
A stator mechanism for a magnetic levitation motor and a stator coil. The stator mechanism includes a stator coil and a stator core. The stator core includes a stator yoke and at least one pair of stator teeth (31). Each of the stator teeth (31) includes a vertical section (311) contacted with the stator yoke and a transverse section (312) at a predetermined angle with the vertical section (311). The stator coil includes an insulating framework (1) and a coil (4). The insulating framework (1) includes an insulating body (11) disposed on an outer surface of the vertical section (311). The insulating body (11) has a first end and a second end opposite to each other in a first extending direction. The first end is provided with a first baffle (12), and the second end is provided with a second baffle (17). The insulating body (11) has a first main surface (111) and a second main surface (112) opposite to each other. The second main surface (112) is a cambered surface protruding outwards away from the first main surface (111). The coil (4) is transversely wound on the first main surface (111) and the second main surface (112) and tightly attached thereto. When a cross-section of the wound coils is of specific shape, coils can be stacked to a maximum density in a limited space.