Rotary Machine Stator Segmentation for Flux Leakage Reduction
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Solution Overview
Problem
Existing electric machines, such as modulated pole machines, suffer from high leakage flux and high manufacturing costs, leading to decreased performance and efficiency.
Innovation Solution
A rotary machine design featuring a first and second stator core section with protruding teeth, a coil between them, and a rotor with permanent magnets, where the teeth of the second stator core section are circumferentially displaced relative to the first, and axially extending pole sections made of soft magnetic material, minimizing leakage flux and optimizing magnetic flux usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If modulated pole machine design is used, then torque output is high, but leakage flux increases and efficiency decreases
Solution Approach 1:
The stator core is divided into two separate stator core sections, each with its own set of teeth. This segmentation allows for optimized magnetic flux paths in each section while reducing leakage flux between poles, thereby maintaining high torque output while improving efficiency
Solution Approach 2:
The invention introduces an axial dimension to the flux paths by using two stator core sections stacked axially with circumferentially displaced teeth. This three-dimensional flux distribution reduces leakage flux while maintaining the high torque characteristics of modulated pole machines
2Power
If modulated pole machine design is used, then torque output is high, but manufacturing cost increases
Solution Approach 1:
Dividing the stator into two separate core sections allows each section to be manufactured independently using standard stamping and assembly processes, reducing overall manufacturing complexity and cost while maintaining the high-performance modulated pole structure
Solution Approach 2:
The circumferential displacement parameter between the two stator core sections is optimized to achieve the desired magnetic flux distribution and torque characteristics while using conventional manufacturing tolerances and standard component dimensions, keeping manufacturing costs manageable
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 design enhances torque production, reduces manufacturing costs, and allows for high electric loading and output, while enabling constant torque and efficient flux concentration, thus improving machine performance and efficiency.
Implementation Method 1
the magnetic flux from the permanent magnets and the coil may be more efficiently used
Implementation Method 2
the coil often is easy to manufacture
Implementation Method 3
axially extending pole sections made from soft magnetic material
Data Source
Figure 1~2
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Figure 5~6
AI summary
An electrical, rotary machine, according to the invention may include a first stator core section being substantially circular and including a plurality of teeth, a second stator core section being substantially circular and including a plurality of teeth, a coil arranged between the first and second circular stator core sections, and a rotor including a plurality of permanent magnets. The first stator core section, the second stator core section, the coil and the rotor are encircling a common geometric axis, and the plurality of teeth of the first stator core section and the second stator core section are arranged to protrude towards the rotor. Additionally the teeth of the second stator core section are circumferentially displaced in relation to the teeth of the first stator core section, and the permanent magnets in the rotor are separated in the circumferential direction from each other by axially extending pole sections made from soft magnetic material.