Multi-Material Segmented Stator for Rotating Electric Machines
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Solution Overview
Problem
Existing methods for making stators for rotating electric machines using multiple soft-magnetic materials lack a viable approach to optimize geometry and cost-effectiveness, despite recognizing the need for different magnetic flux densities in teeth and yoke components.
Innovation Solution
A method involving stamping or cutting laminations from high saturation induction and silicon steel materials, stacking, bonding with adhesives, and heat treating to achieve desired magnetic and mechanical properties, with varying lamination thicknesses and materials distribution to optimize performance and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multi-material concept is used to make teeth and yoke from different magnetic materials, then magnetic efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The stator is divided into separate tooth segments and yoke segments that can be manufactured independently using different magnetic materials. Tooth segments are made from high saturation induction material while yoke segments use standard silicon steel, allowing optimized magnetic performance in each region without requiring complex multi-material manufacturing processes
Solution Approach 2:
Different magnetic materials are applied to specific regions (teeth vs. yoke) based on their local magnetic flux density requirements. The high saturation induction material is used only where needed in the tooth portions experiencing higher flux densities, while standard material suffices for the yoke, optimizing overall magnetic efficiency while controlling costs
2Loss of energy
If multiple soft magnetic materials are used, then magnetic performance is optimized, but manufacturing cost increases
Solution Approach 1:
The stator is segmented into tooth portions and yoke portions that can be manufactured separately using different materials. This allows the expensive high saturation induction material to be used only in the tooth segments where it provides magnetic performance benefits, while the yoke segments use cost-effective standard silicon steel
Solution Approach 2:
The material selection is optimized by changing the saturation induction parameter strategically - high saturation induction material is applied only to tooth segments experiencing high magnetic flux density, while standard material is used in yoke segments where lower flux density exists, optimizing the balance between performance and cost
3Reliability
If high saturation induction material is used in teeth, then magnetic flux density handling is improved, but material cost increases
Solution Approach 1:
High saturation induction material is applied locally only to the tooth segments where high magnetic flux density handling is required, while standard silicon steel is used in the yoke segments where lower flux density exists, optimizing material cost while maintaining reliability
Solution Approach 2:
The saturation induction parameter is optimized by using high saturation induction material selectively in tooth portions experiencing high magnetic flux density, rather than uniformly across the entire stator, reducing material cost while maintaining magnetic flux density handling capability where needed
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 solution effectively improves the operating performance of rotating electric machines by optimizing magnetic and mechanical properties, achieving efficient magnetic flux distribution and reducing costs through strategic material selection and processing.
Implementation Method 1
Bonding the tooth segment laminations together with an adhesive material and curing the adhesive material
Implementation Method 2
Heat treating the tooth segment stack to obtain a desired combination of magnetic and mechanical properties
Implementation Method 3
Stamping or cutting laminations for the tooth segments of the stator from high saturation induction sheet/strip material
Data Source
AI summary
A method of making a stator for a rotating electrical machine in which a tooth segment from a high saturation induction material and a yoke segment from a silicon steel material. The tooth segment is bond to yoke segment, thereby producing a stator with at least two magnetic saturations.