Magnetic Suspension Bearing Stator Assembly Insulation Design
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Solution Overview
Problem
The existing stator assembly designs for magnetic suspension bearings face challenges in ensuring reliable insulation and efficient assembly, particularly due to the complexity and potential dislocation of insulation trough sheets, which can lead to insufficient strength and disordered connections, complicating the assembly process and reducing efficiency.
Innovation Solution
The proposed stator assembly design features two stator core frames with concave and convex portions that engage securely, along with an annular substrate and tooth insulations, simplifying the assembly process and ensuring reliable insulation by eliminating the need for a separate trough sheet, and includes a circuit board and lead-out hub for improved electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate insulation trough sheet is used to insulate the stator core troughs, then insulation is achieved, but the assembly process becomes complicated and the trough sheet may dislocate during winding
Solution Approach 1:
The patent merges the insulation function directly into the stator core frame structure by providing insulating coatings on the inner circumferential surface of the frame. This eliminates the need for separate insulation trough sheets, thereby simplifying the assembly process while maintaining reliable insulation between the stator core and coil windings.
2Ease of operation
If conventional insulation frames with threading buckles are used to lead out coils, then coil leading is achieved, but the axial dimension exceeds the required range and connection strength is insufficient
Solution Approach 1:
The patent integrates the coil leading function directly into the stator core frame structure. The frame includes positioning structures and guiding features that enable coil leads to be routed and secured within the frame itself, eliminating the need for external threading buckles. This reduces the axial dimension while providing sufficient connection strength through the frame's structural design.
3Reliability
If multiple separate insulation components are used, then insulation coverage is comprehensive, but the assembly process is time-consuming and efficiency is low
Solution Approach 1:
The patent combines multiple insulation functions into a single integrated stator core frame structure. The frame includes insulating coatings on its inner circumferential surface that provide comprehensive insulation coverage for the stator core troughs, eliminating the need for multiple separate insulation components. This significantly reduces assembly steps and improves production efficiency.
4Ease of manufacture
If the stator core frame structure is simplified, then manufacturing cost is reduced, but insulation reliability may be compromised
Solution Approach 1:
The patent integrates insulation functionality directly into the stator core frame structure through insulating coatings applied to the inner circumferential surface. This eliminates the need for additional separate insulation components, simplifying manufacturing while ensuring reliable insulation. The frame structure itself becomes the insulation barrier, maintaining reliability while reducing complexity.
Data Source
AI summary
The present disclosure relates to a stator assembly of a magnetic suspension bearing and a manufacturing method, wherein the stator assembly includes stator cores, coils and two stator core frames, two of the stator core frames being respectively engaged at both ends of the stator core along an axial direction thereof, wherein a concave portion is provided at an engaged end of one of the stator core frames, and a convex portion is provided at an engaged end of the other of the stator core frames, the concave portion and the convex portion are engaged with each other, and each of the coils is wound correspondingly to teeth of the stator cores.