Modular Stator Segments for Electric Machine Repair
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Solution Overview
Problem
High-performance electric machines with large stators face issues of costly production and repair due to damage from overheating or short circuits, often requiring the entire stator to be replaced, especially in industries like aerospace.
Innovation Solution
A modular stator design comprising segmented components with preformed windings and busbars, allowing for removability and replacement of damaged parts, with retention features for secure assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large stator with many teeth/slots is used for high performance machines, then machine performance is improved, but production cost and material cost increase significantly
Solution Approach 1:
The stator is divided into multiple modular segments that can be manufactured separately and assembled together. Each segment contains a portion of the stator teeth and slots, allowing for simplified manufacturing processes and reduced material costs while maintaining the overall performance of a large stator with many teeth/slots.
2Power
If a large stator is used for high performance machines, then machine performance is improved, but repairability deteriorates as the entire stator must be replaced if damaged
Solution Approach 1:
By dividing the stator into modular segments, only the damaged segment needs to be replaced rather than the entire stator. Each segment is designed with attachment features that allow for easy removal and replacement, significantly improving repairability while maintaining high machine performance.
3Power
If a large stator is used for high performance machines, then machine performance is improved, but waste and replacement costs increase when damage occurs
Solution Approach 1:
The modular segment design allows for selective replacement of only the damaged portion, reducing material waste significantly. Instead of discarding an entire large stator, only the affected segment is replaced, thereby reducing both waste and associated replacement costs while maintaining high machine performance.
4Ease of repair
If the stator is designed as modular removable components, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The stator is divided into modular segments with standardized attachment features. While this segmentation improves repairability by allowing individual segment replacement, it does increase structural complexity. The complexity is managed through standardized interfaces and attachment mechanisms that simplify the assembly and disassembly processes.
5Ease of operation
If modular components with attachment features are used, then ease of operation for assembly/disassembly is improved, but manufacturing complexity increases
Solution Approach 1:
The stator is designed as modular segments with attachment features that facilitate easy assembly and disassembly, improving ease of operation. However, manufacturing each segment with precise attachment features does increase manufacturing complexity. This is balanced by the ability to manufacture segments using simpler processes compared to manufacturing a single large stator.
Data Source
Figure 1
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AI summary
A method of constructing a stator for an electric machine, comprising forming multiple components of the stator as individual elements; assembling the components into a stator structure and mounting the stator into a machine housing (1), wherein the individual elements can be individually separated from the housing and from the stator structure and replaced with corresponding elements. Also provided is a stator made according to the method.