Segmented Motor Core With SMC Groove and Laminated Insert
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Solution Overview
Problem
The existing segmented core pancake motors face challenges in improving electromagnetic performance while reducing manufacturing difficulty, particularly due to the complexity of processing silicon steel sheets with different dimensions and the poor magnetic permeability of soft magnetic composite (SMC) materials.
Innovation Solution
The solution involves using a laminated core coated with an SMC core, where the SMC core is spliced or wound around the laminated core, reducing processing complexity and enhancing electromagnetic performance by integrating SMC winding bars and embedded grooves for precise positioning, and forming the laminated core with silicon steel or amorphous alloy sheets in a simple structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicon steel sheets with different sectional dimensions are laminated to form segmented core, then electromagnetic performance is improved, but manufacturing complexity increases due to large number of mold specifications
Solution Approach 1:
The core is divided into two distinct segments: a laminated core made from silicon steel sheets for high electromagnetic performance, and an SMC core for structural support and simplified manufacturing. This segmentation allows each part to be optimized independently - the laminated portion maintains excellent magnetic properties while the SMC portion enables easier, more standardized production processes.
2Ease of manufacture
If SMC integral molding method is adopted to form segmented core, then manufacturing ease is improved, but electromagnetic performance deteriorates due to poor magnetic permeability
Solution Approach 1:
The invention creates a composite core structure combining two different materials: laminated silicon steel sheets and SMC (soft magnetic composite). The laminated core provides superior electromagnetic performance with high magnetic permeability, while the SMC core offers manufacturing advantages through integral molding. This composite approach allows the system to achieve both excellent electromagnetic characteristics and ease of manufacture by leveraging the strengths of each material.
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 simplifies mold specifications, reduces processing difficulty, and achieves higher electromagnetic performance compared to using SMC or laminated cores alone, with improved production efficiency and utilization rates.
Implementation Method 1
the SMC core is coated on a periphery of the laminated core by splicing
Implementation Method 2
a coil is directly wound around a periphery of the SMC core
Implementation Method 3
the laminated core is formed by a plurality of laminations through laminating
Data Source
AI summary
A segment core and an axial flux motor. The segment core is formed by covering an SMC core (100, 100′) over an outer peripheral surface of a laminated core (200, 200′). An outer surface of the segment core, which can not be processed easily, is shaped by processing the easily shapeable SMC core (100, 100′). The entire structure of the laminated core (200, 200′) is relatively simple, and thus a mold for processing the laminated core (200, 200′) requires simpler specifications. Moreover, the mold can be used to perform processing easily, thereby reducing difficulties of processing the segment core. The segment core has better electromagnetic performance than a segment core solely using an SMC material, and has a higher core utilization rate than a segment core solely using a laminated core (200, 200′).