Electric Motor Stator Segmentation for Tooth Uniformity
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Solution Overview
Problem
Conventional electric motor manufacturing methods face challenges in reducing non-uniformity in tooth shapes and magnetic characteristics, and securing sufficient rigidity, especially when forming a large number of teeth through punching processing.
Innovation Solution
The electric motor design involves a rotor with a yoke and magnet, and a stator formed by stacking electromagnetic steel sheet layers with two teeth each, arranged in alternating phases to reduce shape non-uniformity and enhance rigidity, where the electromagnetic steel sheets are annularly arranged with two types of phases shifted by one tooth, providing a three-dimensional structure for improved rigidity and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of teeth are formed simultaneously by punching processing, then productivity is improved, but manufacturing precision deteriorates due to non-uniformity in tooth shapes
Solution Approach 1:
The electromagnetic steel sheet is divided into multiple sections, each containing a predetermined number of teeth (e.g., 2 teeth per section). These sections are then annularly arranged and stacked to form the complete stator core. This segmentation allows each section to be precisely formed while maintaining overall productivity through parallel arrangement of multiple sections.
2Ease of manufacture
If an annular integrated member with magnetic orientation is used, then manufacturing is simplified, but manufacturing precision deteriorates due to non-uniformity in magnetic characteristics of respective teeth
Solution Approach 1:
The stator core is segmented into multiple electromagnetic steel sheet sections that are annularly arranged and stacked. This segmentation breaks the magnetic orientation influence of a single large annular member, allowing more uniform magnetic characteristics across all teeth while maintaining manufacturing simplicity through standardized section formation.
Solution Approach 2:
The invention transitions from a single-plane annular arrangement to a three-dimensional stacked structure with multiple electromagnetic steel sheet layers. This dimensional change distributes the magnetic orientation effects across multiple layers, reducing non-uniformity in magnetic characteristics while maintaining ease of manufacture through standardized stacking procedures.
3Weight of moving object
If electromagnetic steel sheets are stacked to form the stator core, then weight is reduced, but rigidity deteriorates due to insufficient structural stability
Solution Approach 1:
The stator core is constructed by stacking multiple electromagnetic steel sheet layers in the axial direction, creating a three-dimensional structure. This dimensional approach maintains the weight advantages of thin sheets while providing structural rigidity through the stacked configuration and radial arrangement of teeth sections across multiple layers.
Solution Approach 2:
The electromagnetic steel sheets are pre-formed into sections with specific tooth arrangements before stacking. This preliminary formation ensures precise tooth geometry and magnetic characteristics are established prior to assembly, while the subsequent stacking process provides the necessary structural rigidity without adding excessive weight.
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 effectively reduces non-uniformity in tooth shapes and magnetic characteristics while ensuring sufficient rigidity and efficiency by suppressing magnetic interference, leading to improved motor performance.
Implementation Method 1
an annular integrated member itself has a magnetic orientation. When a non-oriented electromagnetic steel sheet is used, such an influence of the magnetic orientation property is likely to be reduced
Data Source
AI summary
An electric motor includes: a rotor having a rotor yoke and a magnet; and a stator formed by stacking, in a rotation axis direction of the rotor, a plurality of electromagnetic steel sheet layers in each of which a plurality of electromagnetic steel sheets each having two teeth is annularly arranged. A core of a coil provided in the stator is formed of the teeth stacked in the rotation axis direction, there are two types of phases for arrangement of a plurality of electromagnetic steel sheets in one electromagnetic steel sheet layer, and the stator includes the electromagnetic steel sheet layers having the two types of phases.