Polymer-Embedded Stator Assembly for Low-Waste Motor Manufacturing
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Solution Overview
Problem
Existing stator manufacturing processes for electric motors and generators are costly, complex, and generate significant waste due to operations like blanking, photo-engraving, or laser cutting, and they are difficult to integrate with other electronic components.
Innovation Solution
A manufacturing process involving laminations made of ferromagnetic material with arched slab-shaped sections that are assembled with interlocking coupling means, embedded in a polymer material, and molded to form a stator support with integrated insulation and housing for electronic components, allowing easy integration with magnetic sensors and battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional blanking, photo-engraving or laser cutting operations are used to manufacture laminations with annular shape, then stators can be produced, but considerable debris and waste of material are generated
Solution Approach 1:
The invention divides the stator body into multiple individual laminations that are assembled together. Each lamination is a separate component that can be manufactured independently using less wasteful processes, and then combined through interlocking coupling means to form the complete stator structure.
Solution Approach 2:
The invention uses composite construction by assembling multiple ferromagnetic lamination layers with insulating materials between them. This layered composite approach allows for more efficient material utilization during manufacturing while maintaining the required electromagnetic properties of the stator.
2Reliability
If sheets of insulating paper, special paints or other separating materials are applied around the polar protrusions to electrically insulate windings from laminations, then electrical insulation is achieved, but the production process becomes particularly difficult and complicated
Solution Approach 1:
The invention combines the electrical insulation function with the structural lamination design by incorporating insulating materials as integral parts of the lamination assembly process. The insulating sheets are positioned between laminations during assembly, merging the insulation application with the structural construction rather than treating them as separate operations.
Solution Approach 2:
The lamination structure itself provides the electrical insulation through the inherent insulating properties of the material layers and the design of the assembly process. The insulating sheets are self-positioned during lamination assembly, eliminating the need for separate, complex insulation application operations.
3Adaptability or versatility
If magnetic sensors must be fastened to the stator at predefined positions, then position detection is enabled, but it takes time for the assembly
Solution Approach 1:
The invention prepares the stator structure in advance by incorporating predefined mounting positions and coupling means during the lamination assembly process. These preparation features are built into the stator structure before final component assembly, allowing magnetic sensors and other components to be quickly installed without requiring complex positioning or additional machining operations.
Data Source
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AI summary
The manufacturing process of stators for electric motors and/or generators comprises the phases of: - providing (I) a plurality of laminations (1) made of ferromagnetic material; - assembling (II) the laminations (1) with one another to form a ferromagnetic stator body (2) of annular conformation provided with a plurality of polar protrusions (3); - introducing (III) the ferromagnetic stator body (2) inside a mould (4) for plastic/polymer material molding; - injecting (IV) at least one plastic/polymer material (P) inside the mould (4) to obtain a stator support (5) wherein the ferromagnetic stator body (2) is at least partly embedded, the mould (4) being shaped in such a way that the stator support (5) comprises a plurality of coating walls (6) in the plastic/polymer material (P) that cover at least part of the polar protrusions (3); - mounting (V) a plurality of electrical windings (29) around the coating walls (6).