Magnetic Core Notch Structure for Compact Coil End Routing
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Solution Overview
Problem
Existing magnetic cores in rotary electric machines lack a secure region for leading out both ends of a coil without increasing the size of the machine, and the fabrication process can damage insulation coatings due to sharp notch surfaces.
Innovation Solution
A magnetic core design with a core back part and teeth part featuring notch surfaces between selected end and side surfaces, allowing both coil ends to be led out without size increase, and using soft magnetic powder fabrication to avoid cutting processes and reduce chipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional magnetic core design is used, then the structure is simple, but there is no secure region for leading out both ends of the coil
Solution Approach 1:
The magnetic core is divided into distinct functional regions: a core back part with end surfaces and side surfaces, and a teeth part with multiple teeth. Notch surfaces are introduced at specific locations to create dedicated regions for coil end leading out. This segmentation allows the coil ends to be led out through specific notches without complicating the overall core structure, as each part serves its specific function.
Solution Approach 2:
Notch surfaces are introduced as intermediary features between the core back part and the teeth part. These notches serve as intermediate regions that facilitate the leading out of coil ends, providing a dedicated pathway that does not require major structural modifications to the magnetic core itself.
2Ease of manufacture
If cutting processes are used to form notch surfaces, then the notch surfaces can be created, but the insulation coating is damaged
Solution Approach 1:
The patent replaces mechanical cutting processes with a molding process for forming notch surfaces. The magnetic core is molded with pre-formed notch surfaces that have rounded corners, eliminating the need for subsequent cutting operations. This substitution of the manufacturing method prevents damage to the insulation coating while still achieving the required notch geometry.
Solution Approach 2:
The notch surfaces are formed in advance during the molding process, before the insulation coating is applied or before any cutting operations would be performed. By preliminary forming the notches with rounded corners in the molded state, the patent prevents subsequent cutting operations that would damage the insulation coating.
3Area of stationary object
If the rotary electric machine size is increased to secure coil leading out region, then there is enough space for coil ends, but the machine becomes larger
Solution Approach 1:
Instead of increasing the overall size of the rotary electric machine, the patent introduces localized notch surfaces at specific positions on the magnetic core. These notches create dedicated regions for coil end leading out only where needed, without enlarging the entire machine. The local modification provides the necessary space while maintaining the compact overall dimensions.
Solution Approach 2:
The patent utilizes the dimensional space created by introducing notch surfaces at the intersections of end surfaces and side surfaces. By creating these notches in the radial and axial directions, the patent effectively uses the existing three-dimensional space of the magnetic core more efficiently, providing coil leading out regions without increasing the machine's external dimensions.
Data Source
AI summary
A magnetic core that includes: a core back part; and a teeth part, wherein the core back part has: a first end surface directed in an axial direction and extending along a rotary axis of a rotary electric machine, and a second end surface directed in a direction opposite from the axial direction, and a first side surface and a second side surface positioned side by side in a circumferential direction about the rotary axis, and the core back part has a shape where a notch surface is interposed in between at least one of: (1) the first end surface and the first side surface, (2) the first end surface and the second side surface, (3) the second end surface and the first side surface, and (4) the second end surface and the second side surface.