Modular Conical Stator Pole Assembly for Electric Motors
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Solution Overview
Problem
Conventional electric motor designs are large, heavy, and costly to ship due to significant air space usage, require special handling, and are not modular, making them expensive to retool for design changes and maintain, with suboptimal power density and torque due to cylindrical shapes.
Innovation Solution
A modular conical stator assembly with tapered stator poles formed from ferrous magnetic metal powder particles, allowing for increased torque and power density through a larger moment arm and active length, enabling efficient use of space and easy maintenance by assembling individual components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional cylindrical motor designs are used, then the motor structure is simple and easy to manufacture, but the motor is large, heavy, and has low power density due to significant air space usage
Solution Approach 1:
The patent applies asymmetry by transitioning from a conventional cylindrical stator geometry to a conical stator geometry. The conical shape eliminates the large air space inherent in cylindrical designs by conforming more closely to the rotor, thereby increasing the active magnetic interaction area and power density without proportionally increasing weight
Solution Approach 2:
The patent introduces a dimensional change by adding the conical angle dimension to the traditional cylindrical geometry. This creates a three-dimensional optimization where the stator tapers from a larger diameter at one end to a smaller diameter at the other, maximizing the use of available radial and axial space for magnetic interaction
2Adaptability or versatility
If conventional non-modular motor designs are used, then the manufacturing process is established, but retooling for design changes is expensive and requires production downtime
Solution Approach 1:
The patent applies segmentation by dividing the stator into multiple removable pole assemblies that can be independently manufactured and replaced. Each pole assembly can be produced separately using standardized tooling, and design changes only require retooling for the specific pole components rather than the entire stator, significantly reducing retooling costs and production downtime
3Area of stationary object
If conventional cylindrical designs are used, then the manufacturing process is established, but the available mounting space is not maximized
Solution Approach 1:
The conical shape provides asymmetric geometry that better conforms to typical mounting spaces and equipment bays, allowing the motor to utilize available space more efficiently compared to the symmetric cylindrical shape that leaves unused volume
4Force
If conventional cylindrical designs are used, then the structure is simple, but the moment arm is limited and torque is reduced
Solution Approach 1:
The conical geometry adds a radial dimension variation along the axial length, creating a varying moment arm that increases torque production. The larger radius at one end of the cone provides a longer moment arm for the magnetic forces, generating increased torque without significantly complicating the manufacturing process
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 conical design enhances torque and power density by maximizing radial displacement and active length, reduces motor losses, and allows for on-site maintenance of individual stator components, improving installation efficiency and reducing manufacturing costs.
Implementation Method 1
The winding support is usually comprised of a soft magnetic material which traditionally is made of laminations of selected steel materials. The laminations are insulated from each other in order to reduce eddy currents. It's become known to replace laminated steel materials of the stator or rotor cores with ferro magnetic powder particles. These ferro magnetic particles are compacted in a powder metallurgy operation to form the winding support.
Implementation Method 2
The interaction between the stator and the rotor is caused by the interaction on a magnetic field generated by either the stator or the rotor. Such magnetic field is usually generated or induced by electric currents in a winding placed on either the stator or the rotor or both.
Implementation Method 3
The forces imparted on the rotor are a function of the interaction of the stator and the rotor magnetic fields and the moment arm of the rotor calculated by the radial displacement of the magnetic field of the rotor with respect to the axis of the rotor.
Data Source
AI summary
The modular conical stator pole provides an improved conical stator assembly on electrical machines. The improved conical stator pole assembly comprises a plurality of stator poles, each pole comprising an assembly having a coil secured on a soft magnetic composites (SMC) stator pole tooth by inserting a winding support through the open core of the coil and attaching a back iron and a stator face to either end of the winding support. Each stator pole having a parallelogram shaped cross section for forming a conical shaped rotor space when the stator poles are assembled having the back irons bearing against each other to space the coils apart and form a conical shaped outside profile of the stator pole assembly. The conical stator having a small end and a big end. The tooth comprising a winding support integrally molded with either the back iron or the face.