Magnetoelectric Generator Stator Core Joining

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Solution Overview

Problem

Conventional magnetoelectric generators with dowel crimping integration of stator cores suffer from low joining strength between end plates and intermediate plates, leading to gaps and pinholes in the epoxy resin coating, which compromises the structural integrity and insulation.

Innovation Solution

A magnetoelectric generator design featuring a laminated stator core with dowel crimped intermediate plates and end plates that engage through a receiving aperture and bent portions, enhancing the joining strength and reducing gaps, thereby minimizing pinholes in the resin coating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If dowel crimping is used to integrate the stator core, then the manufacturing process is simple, but the joining strength between end plates and intermediate plates is low

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidjoining strength between end plates and intermediate plates

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The stator core is divided into multiple intermediate plates that are laminated together, with end plates positioned on opposite sides. This segmentation allows for modular assembly while maintaining structural integrity through the receiving aperture engagement system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The receiving aperture is formed by bending portions of the intermediate plates inward, creating a nested structure where the bent portions fit into the receiving aperture. This nested design provides strong mechanical engagement between the end plates and intermediate plates without requiring complex external fasteners.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of manufacture

If dowel crimping is used to integrate the stator core, then the manufacturing process is simple, but gaps arise between end plates and intermediate plates

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidgap formation between plates

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The receiving aperture with bent portions creates a nested engagement structure that physically prevents gaps from forming between the end plates and intermediate plates. The bent portions fit tightly within the receiving aperture, ensuring close contact and eliminating spaces where gaps could occur.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The bent portions of the intermediate plates act as flexible elements that can deform during assembly to accommodate minor misalignments, then maintain constant contact pressure to prevent gap formation. This flexibility compensates for manufacturing tolerances while preventing gap creation.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If dowel crimping is used to integrate the stator core, then the manufacturing process is simple, but pinholes form in the epoxy resin coating

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidresin coating quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The nested engagement structure of the receiving aperture and bent portions eliminates gaps between plates, thereby preventing the formation of pinholes in the epoxy resin coating. By ensuring tight contact between plates, the coating can be applied uniformly without defects.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The receiving aperture design proactively prevents gap formation before the epoxy resin coating is applied. By eliminating the root cause (gaps between plates) before the coating process, pinhole formation is prevented in advance, ensuring high-quality coating without requiring additional corrective measures.

Inventive Principle:

Principle #9Preliminary anti-action

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 improved joining strength between end plates and intermediate plates reduces pinholes in the resin coating, increases the structural integrity of the stator core, and enhances the winding process by preventing collapse and insulation failure, while allowing for a lightweight and efficient manufacturing process.

Implementation Method 1

a magnetoelectric generator that generates power by electromagnetic induction between a permanent magnet and a generating coil due to rotation of a flywheel

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS7368844B2Magnetoelectric generator

Publication Date: 2008.05.06 MITSUBISHI ELECTRIC MOBILITY CORP

AI summary

A stator core includes: a laminated body in which a plurality of intermediate plates that have dowels are laminated so as to be integrated by dowel crimping between layers; and a pair of end plates that are disposed so as to be positioned on opposite sides of two end surfaces of the laminated body, and a receiving aperture that extends parallel to an axis of rotation is formed on the laminated body, a bent portion is disposed on the end plates, and the end plates are joined to the laminated body by engaging the bent portion in the receiving aperture.