Segmented Stator Core Assembly for Even Air Gaps and Less Scrap
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Solution Overview
Problem
Existing methods for manufacturing stator cores in electric motors face issues with maintaining concentricity of teeth, leading to uneven air gaps, increased scrap material, and reduced coupling strength, which affect motor output and productivity.
Innovation Solution
A stator design featuring a plurality of split cores with hingedly connected yoke parts and teeth parts, allowing for even air gaps and enhanced concentricity, reduced scrap material, and improved coupling strength through features like cutting parts, connection parts, and fitting coupling portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a split core with a single yoke and single teeth is used, then manufacturing is simplified, but concentricity of the teeth cannot be easily maintained when coupled into a circular shape
Solution Approach 1:
The stator core is divided into multiple segmented cores (e.g., four segments) instead of a single split core. Each segmented core includes multiple yoke parts and teeth parts that can be independently manufactured and then assembled. This segmentation allows for better control of concentricity during assembly while maintaining manufacturing simplicity through modular production.
2Device complexity
If a shape with a single yoke and single teeth is used for motors with a relatively small number of teeth and slots, then the structure is simplified, but the length of the yoke becomes relatively great compared to the width of the teeth, increasing the ratio of scraps to base material
Solution Approach 1:
By dividing the stator core into multiple segmented cores, the yoke length is effectively reduced in each segment while maintaining the overall circular structure. This allows for more efficient utilization of the base material, reducing the scrap ratio compared to a single large-yoke design.
Solution Approach 2:
The design transitions from a single-plane yoke structure to a multi-segmented three-dimensional assembly. This dimensional change allows optimization of material distribution, reducing excessive yoke length while maintaining structural integrity and magnetic path efficiency.
3Ease of manufacture
If a split core is used for manufacturing, then assembly is facilitated, but coupling strength of the yoke part in the radial direction deteriorates after coupling
Solution Approach 1:
The stator core is divided into multiple segmented cores with coupling protrusions and coupling recesses that interlock in the radial direction. This segmented design with specialized coupling features maintains assembly facilitation while significantly improving radial coupling strength compared to traditional split cores.
4Productivity
If traditional stator core manufacturing methods are used, then production is straightforward, but the air gap between the stator and rotor becomes uneven, deteriorating motor output
Solution Approach 1:
The multiple segmented cores can be independently precision-manufactured and then assembled with controlled positioning. This segmentation enables better control of the air gap uniformity between the stator and rotor, improving motor output reliability while maintaining production efficiency through modular assembly.
Data Source
AI summary
A motor including: a stator; and a rotor rotating about the stator. The stator has: a stator core having a plurality of split cores respectively having a plurality of teeth and slots and coupled into a ring shape; and a stator coil inserted in the slots. The plurality of split cores has: a plurality of yoke parts positioned adjacent to each other; a plurality of teeth parts respectively protruding from the plurality of yoke parts in the radial direction; a cutting part cut in the radial direction between the yoke parts which are adjacent to each other; and a connection part for connecting the yoke parts which are adjacent to each other so as to be able to relatively rotate. Therefore, the size of scraps can be reduced when manufacturing the stator core.