Molded Core Assemblies for Motor-Generators with Preform Windings
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Solution Overview
Problem
The manufacturing of rotary electric machines, such as motor-generator units, faces challenges in optimizing noise, vibration, and harshness, while also requiring additional processes for winding insertion and connection, which increases size and complexity.
Innovation Solution
The use of preform windings and a molded core formed from a curable material with a ferromagnetic filler, such as ferrosilicon, where the molded core includes slots conforming to the windings and integrated cooling conduits, allowing for in situ winding cooling and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional laminated electrical steels are stacked and windings are inserted into slots, then the stator can be manufactured with conventional processes, but manufacturing tolerances and machining considerations increase overall size and complexity
Solution Approach 1:
The patent merges the stator core and windings into a single integrated molded assembly. The curable material formulation combines ferromagnetic particles (providing magnetic properties) with resin and curing agents, allowing both the core structure and windings to be formed in one molding process rather than separate assembly steps.
Solution Approach 2:
The patent uses composite materials in the curable material formulation, combining ferromagnetic particles (20-80 wt%) with resin (10-60 wt%), curing agents (5-30 wt%), and optional additives. This composite approach provides both structural integrity and magnetic properties within a single material system.
2Reliability
If additional processes are required to complete windings after insertion (such as welding end windings), then the winding circuit can be formed, but tooling design constraints and overall size increase
Solution Approach 1:
The patent performs preliminary action by pre-forming the windings as integral parts of the molded assembly during the core molding process itself. The curable material is molded to directly form both the core structure and the winding circuits in one operation, eliminating subsequent welding or connection processes that would require additional tooling and steps.
3Ease of manufacture
If conventional stator manufacturing is used, then standard production methods can be employed, but noise, vibration, and harshness are not optimized
Solution Approach 1:
The patent applies parameter changes by modifying the physical and magnetic properties through the curable material formulation. By adjusting ferromagnetic particle concentration (20-80 wt%), resin content (10-60 wt%), and curing agent ratios (5-30 wt%), the magnetic permeability, coercivity, and mechanical damping characteristics are optimized to reduce noise, vibration, and harshness while maintaining manufacturability.
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
This approach optimizes noise, vibration, and harshness, reduces the overall size of the motor-generator, and decreases the part count, while enabling efficient winding integration and cooling, thereby enhancing the performance and efficiency of the motor-generator units.
Implementation Method 1
a molded core formed from a curable material with a ferromagnetic filler, such as ferrosilicon
Implementation Method 2
a molded core formed from a curable material with a ferromagnetic filler, such as ferrosilicon
Data Source
AI summary
Systems, methods and motor-generators with preform windings and a molded core are described. The preform windings include a first end, a second end, and a plurality of in-slot portions extending from the first end to the second end. The molded core includes a plurality of slots. Each of the plurality of slots including a respective in-slot portion disposed therein. Each of the plurality of slots includes a wall conforming to an outer profile of the respective in-slot portion.