Segmented Stator Tooth Assembly With Clamped Flange Alignment

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Solution Overview

Problem

Existing stator assemblies for electrical machines face challenges in aligning and securing individually manufactured stator teeth without expensive machining, which affects the efficient transfer of electromagnetic flux and heat while being cost-effective.

Innovation Solution

A stator assembly design featuring individually formed stator teeth with radially extended body portions, central flanges for engagement, and clamping mechanisms that exert a radially inward force to hold the teeth together, allowing for easy alignment and secure assembly while minimizing material waste and machining costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If individually manufactured stator teeth are joined together without expensive machining, then manufacturing cost is reduced, but alignment precision deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The stator is divided into multiple individually manufactured stator teeth that are joined together using clamping mechanisms, allowing each tooth to be manufactured separately at lower cost while maintaining overall assembly precision through the engagement features and clamping system

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Clamping mechanisms serve as intermediary components between individually manufactured stator teeth, providing a means to join the teeth together with adequate alignment without requiring expensive machining of the teeth themselves

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If expensive machining is performed on stator teeth, then alignment precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvealignment precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Engagement features such as central flanges are incorporated into the stator teeth during the initial manufacturing process, enabling precise alignment to be achieved during assembly without requiring subsequent expensive machining operations

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If stator teeth are held together with strong clamping force, then assembly stability is improved, but stress on individual teeth increases

Engineering Contradiction:

Improveassembly stabilityVSAvoidstress on stator teeth

Core Design Contradiction:

Stability of the object's compositionVSStress or pressure

Solution Approach 1:

Multiple clamping mechanisms are distributed around the stator assembly, sharing the clamping load across several points rather than concentrating stress on individual stator teeth, thereby maintaining assembly stability while reducing localized stress

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4465486A1Stator assembly

Publication Date: 2024.11.20 HAMILTON SUNDSTRAND CORP

Figure 1
Figure 2a~2b
Figure 2c

AI summary

A stator assembly for an electrical machine, including stator teeth (200) which are individually formed and are spaced azimuthally from each other. Each stator tooth includes an azimuthally extending central flange (204, 208) arranged to engage with the central flange of an adjacent stator tooth. The stator assembly includes clamping elements (502) which are arranged between the stator teeth and are arranged to exert a radially inward force on each stator tooth, to hold the stator assembly together.