Segmented Core Motor Stator Assembly via Dowel Clamping
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Solution Overview
Problem
The existing methods for connecting and fixing segmented cores in an annular shape for motor stators are complex, time-consuming, and prone to issues like distortion, inadequate adhesion, and excessive adhesive application, which affect the magnetic characteristics and assembly efficiency.
Innovation Solution
The use of laminated cores with clamping dowels, where first and second dowels are formed on the plates to securely connect and fix the laminated plates by pressure-fitting rings to the end faces of the segmented core connected body, eliminating the need for welding or excessive adhesive, and allowing for a simple and efficient integration of the segmented core connected body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If segmented cores are connected and fixed by welding, bonding, or other means, then the segmented cores can be joined to form an annular stator core, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The invention divides the stator core into multiple segmented cores that can be assembled separately and then connected. Each segmented core is formed by laminating multiple laminated plates with engaging protrusions and engaging grooves, allowing modular assembly and reducing overall assembly time while maintaining connection reliability through the engagement structures.
Solution Approach 2:
The engaging protrusions and engaging grooves are pre-formed on the laminated plates before assembly. This preliminary action allows the segmented cores to be quickly connected by simply engaging these pre-formed structures, eliminating the need for time-consuming welding or bonding operations during final assembly.
2Ease of manufacture
If segmented cores are mechanically engaged using engaging protrusions and engaging grooves, then assembly is simplified, but the connection strength and stability are insufficient
Solution Approach 1:
The invention combines multiple engagement methods: mechanical engagement through engaging protrusions and grooves, plus clamping engagement through clamping protrusions and grooves. This merging of engagement mechanisms provides both assembly simplicity and strong connection stability, as the dual engagement system prevents displacement while maintaining ease of assembly.
Solution Approach 2:
The invention uses composite engagement structures combining different geometric features (engaging protrusions for mechanical interlocking, clamping protrusions for friction-based holding). This composite approach creates a connection system that is both simple to assemble and strong enough to prevent displacement under operational loads.
3Stability of the object's composition
If laminated plates are connected by pressure-fitting with dowels, then the laminated plates are securely fixed, but the assembly process becomes more complex
Solution Approach 1:
The engaging protrusions and grooves serve multiple functions: they provide mechanical interlocking between laminated plates, guide alignment during assembly, and prevent displacement in both radial and axial directions. This multi-functionality reduces the need for separate components like dowels, simplifying the overall assembly process while maintaining laminated plate stability.
4Strength
If welding or bonding is used to connect segmented cores, then strong connection is achieved, but distortion and magnetic characteristic degradation occur
Solution Approach 1:
The invention replaces thermal connection methods (welding and bonding) with purely mechanical engagement systems consisting of engaging protrusions, engaging grooves, clamping protrusions, and clamping grooves. This substitution eliminates thermal effects that cause distortion and magnetic characteristic degradation, while maintaining strong connection strength through mechanical interlocking and friction-based clamping.
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 significantly reduces assembly time, prevents distortion, ensures accurate adhesion, and maintains magnetic characteristics, while simplifying the integration process and eliminating issues associated with welding and adhesive application.
Implementation Method 1
a first ring is pressure-fitted and fixed to a first annular end face of a segmented core connected body
Data Source
Figure 1
Figure 2(a)~2(d)
Figure 3(a)~3(c)
AI summary
Stator core (3) of motor stator (1) is equipped with a segmented core connecting body (30) which connects in an annular shape a segmented core (2) having a structure whereby laminated core plates (12) are connected and held in place in a laminated state. To connect and fix core laminated plates (12) by clamping, first and second dowels (12a, 12b) formed in each core laminated plate (12) are used to connect and fix common rings (33) by pressure-fitting them to the first and second end faces (31, 32) at either side of the segmented core connecting body (30), thus integrating the segmented core connecting body (30). The segmented core connecting body (30) can be integrated with a simple operation, thus significantly reducing the assembly time for the stator core (3).