Motor Laminated Core Caulking Positioning to Reduce Core Loss
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Solution Overview
Problem
The existing laminated core structure of motors experiences core loss due to caulking, which disrupts magnetic balance and motor characteristics, particularly in the rotor iron core where caulking uneven parts interfere with magnetic flux.
Innovation Solution
The laminated core structure is designed such that the caulking uneven parts of both the stator and rotor iron cores are positioned away from the main magnetic path, with the stator's caulking uneven parts located outside the minimum circle radius and the rotor's within the yoke width, minimizing their impact on magnetic flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If caulking uneven parts are formed in the magnetic path to fasten laminated cores, then the mechanical fastening strength is improved, but core loss increases due to magnetic resistance at the caulking parts
Solution Approach 1:
The invention extracts the harmful caulking uneven parts from the magnetic path by positioning them in non-magnetic path areas. The caulking parts are deliberately placed in regions where magnetic flux does not pass, such as the outer peripheral portions of the stator and rotor cores, thereby eliminating their negative impact on magnetic flux while maintaining their mechanical fastening function.
Solution Approach 2:
The invention applies different functional requirements to different regions of the laminated core. The magnetic path regions are optimized for magnetic flux conduction with smooth surfaces, while the non-magnetic path regions (outer peripheral portions) are optimized for mechanical fastening with caulking uneven parts. This local differentiation allows each region to fulfill its specific function without compromising the other.
2Device complexity
If caulking uneven parts are positioned in the magnetic path, then the laminated core structure is simplified, but motor characteristics are adversely influenced due to disrupted magnetic balance
Solution Approach 1:
The invention extracts the caulking function from the magnetic path region and relocates it to non-magnetic path regions. By positioning caulking uneven parts in the outer peripheral portions where magnetic flux does not pass, the magnetic balance of the motor is preserved while still achieving effective mechanical fastening of the laminated core structure.
Solution Approach 2:
The invention transitions the caulking function from a two-dimensional consideration (within the magnetic path plane) to a three-dimensional spatial arrangement by utilizing the outer peripheral regions and radial dimension. This dimensional shift allows caulking parts to be positioned outside the magnetic flux path while maintaining structural integrity.
Data Source
AI summary
The laminated core structure of a motor includes a stator iron core formed by laminating a plurality of stator iron core thin sheets in which a plurality of magnetic poles are provided at fixed intervals along the circumferential direction on the inner peripheral side so as to project toward the center direction, and a rotor iron core arranged on the axis line of the stator iron core concentrically with the stator iron core and formed by laminating a plurality of disc-shaped rotor iron core thin sheets, the stator iron core and the rotor iron core each being fastened by caulking the plurality of thin sheets to each other. The core loss produced by caulking is decreased by particular placement of the center of a caulking uneven part of the stator iron core thin sheet and the center of a caulking uneven part of the rotor iron core thin sheet.