Segmented Stator Core Assembly for Coupling Strength and Concentricity
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Solution Overview
Problem
Existing electric motors for handheld devices face issues with insufficient coupling force between segmented yokes and teeth, leading to deformation, non-uniform air gaps, increased vibration and noise, and decreased output due to assembly tolerance and magnetic reluctance.
Innovation Solution
The electric motor incorporates a stator core design with assembly connectors between adjacent yokes and teeth, allowing for controlled interference fitting and temperature adjustment to enhance coupling strength and maintain uniform gaps, while using magnetic steel sheets for insulation and reduced magnetic reluctance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If segmented-core is used to reduce scrap and improve winding workability, then manufacturing efficiency is improved, but coupling force between yokes becomes insufficient
Solution Approach 1:
The stator core is divided into multiple yokes that are coupled together through coupling portions, allowing for improved winding workability while maintaining structural integrity through proper coupling design
Solution Approach 2:
The coupling portions integrate multiple functions: mechanical coupling between yokes, structural support for teeth, and maintenance of air gap uniformity, combining several requirements into a single structural element
2Strength
If coupling portion size is increased to improve coupling force, then coupling strength is improved, but deformation of yoke and tooth becomes more difficult to suppress
Solution Approach 1:
The coupling portion has different local properties: a larger overall size for strong coupling, but specifically designed coupling surfaces with appropriate fit characteristics to prevent deformation while maintaining concentricity
Solution Approach 2:
The coupling structure combines different material properties and structural characteristics - magnetic steel sheets for magnetic performance, with specific geometric features for mechanical coupling and deformation prevention
3Stability of the object's composition
If yokes are loosely fitted to prevent deformation, then deformation is suppressed, but assembly tolerance causes decrease in concentricity
Solution Approach 1:
The coupling portion is designed with predetermined geometric features that compensate for assembly tolerances, ensuring concentricity is maintained despite loose fitting conditions
4Strength
If adhesive is applied to coupling portion to prevent loose fit, then coupling strength is improved, but assembly complexity increases
Solution Approach 1:
The mechanical coupling design replaces the need for adhesive bonding, achieving strong coupling through precise geometric fitting and mechanical interlocking rather than chemical bonding
Data Source
AI summary
An electric motor includes a stator and a rotor which is rotatable with respect to the stator. The stator has: a stator core; and a stator coil which is wound around the stator core. The stator core has: a yoke which is segmented in the circumferential direction of the stator; an assembly connector which is coupled between two yokes which are continuously disposed along the circumferential direction of the stator; and teeth which protrude along the radial direction of the stator from the inner surface of the assembly connector.