Rounded Magnetic Wedge Geometry for Smooth Stator Slot Insertion
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Solution Overview
Problem
Conventional magnetic wedges in dynamo-electric machines have sharp angular corners that can be damaged during insertion, leading to contamination and installation difficulties, and may break due to corner catching and bending.
Innovation Solution
A magnetic wedge with rounded corners and a composite material of Fe-based soft magnetic particles and an electrically insulating oxide phase, manufactured using a pressing method with a die and punch having rounded openings, allowing for smooth insertion and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the magnetic wedge is machined to have sharp angular corners, then the manufacturing precision and shape accuracy are improved, but the corners are easily damaged during insertion causing contamination and installation difficulties
Solution Approach 1:
The patent applies curvature by rounding the corners of the magnetic wedge from a sharp angular shape to a rounded shape with a specified radius. This curvature modification eliminates the stress concentration points at sharp corners, preventing damage during insertion while maintaining the required dimensional accuracy of the wedge shape. The rounded corners enable smooth insertion into the slot opening without catching or bending.
2Manufacturing precision
If the magnetic wedge has sharp angular corners, then the manufacturing precision is improved, but the corners may be caught and bend making insertion difficult or causing breakage
Solution Approach 1:
The patent modifies the sharp angular corners to rounded corners with a specified radius, which eliminates the catching and bending issues during insertion. The curved surface allows the wedge to slide smoothly into the slot opening without getting caught on edges, significantly improving ease of operation while the overall dimensional accuracy is maintained through controlled rounding.
3Manufacturing precision
If conventional machining is used to create the magnetic wedge, then the shape accuracy is improved, but iron powder scatters causing contamination
Solution Approach 1:
The patent employs rounded corner geometry that can be formed through forming processes rather than traditional machining. This approach reduces the generation of iron powder scattering during manufacturing, as the rounded shape can be achieved through die forming or rolling processes that do not involve cutting or grinding operations that generate metal屑.
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 magnetic wedge can be easily installed without damage, reducing contamination and breakage risks, while enhancing the magnetic properties and motor efficiency by minimizing stress concentration and eddy current loss.
Implementation Method 1
the electrically insulating substance may be an oxide phase containing the element M, and the Fe-based soft magnetic particles may be bound by the oxide phase
Implementation Method 2
a composite material made of a ferromagnetic powder such as iron powder and a thermosetting resin is known
Implementation Method 3
A magnetic flux reaching the coil from the rotor can be magnetically shielded by disposing such a magnetic wedge
Implementation Method 4
eddy current loss of the coil can be curbed
Data Source
AI summary
Provided are a magnetic wedge in which insertion of a magnetic wedge in a tooth tip of a dynamo-electric machine can be performed more smoothly, and a method for manufacturing the magnetic wedge. This magnetic wedge is installed in a slot opening of a stator of the dynamo-electric machine, and defining that the dimension of the magnetic wedge in the circumferential direction of the dynamo-electric machine is the width, the projection shape of the magnetic wedge projected on a plane perpendicular to the width direction is a rectangle, parallelogram, or a right angle trapezoid, and the corners of the rectangle, parallelogram, or right angle trapezoid have a rounded shape.