Segmented Stator Core for Motor Coil Turn Density and Wire Loss Reduction
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Solution Overview
Problem
Conventional motors face limitations in increasing coil turns and diameter, reducing wire loss, improving winding efficiency, and minimizing material usage while maintaining output, due to the integral stator core design which restricts size and shape changes.
Innovation Solution
The motor design incorporates a divided stator core with a first and second stator core, symmetrically arranged, allowing for increased coil turns and diameters, reduced wire loss, and improved winding efficiency, while enabling diverse rotor connections and minimizing magnetic flux passage and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the stator core is designed as an integral structure, then the structural strength and magnetic flux continuity are improved, but the slot area becomes small which limits the number of coil turns and coil diameter
Solution Approach 1:
The stator core is divided into multiple independent segments (first stator core and second stator core) that can be assembled together. This segmentation increases the slot area in each segment, allowing for more coil turns and larger coil diameter, while maintaining structural integrity through the assembly of segments.
2Stability of the object's composition
If the stator core is designed as an integral structure, then the magnetic flux passage is continuous, but the wire loss generated in the coil becomes large which reduces motor efficiency
Solution Approach 1:
The stator core is segmented into multiple independent parts, which increases the slot area and allows for more coil turns. This increases the electrical conductivity and reduces wire loss, thereby improving motor efficiency while maintaining adequate magnetic flux continuity through proper segment design and arrangement.
3Device complexity
If the stator core size and shape are kept conventional, then the design is simple, but it is difficult to reduce the material used for fabricating the stator core
Solution Approach 1:
The stator core is divided into multiple segments that can be independently designed and manufactured. This allows for optimization of material usage in each segment, reducing the total material required while maintaining the necessary structural and magnetic properties. The segmented design also enables more efficient packing and assembly.
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 design enhances motor efficiency, output intensity, and reduces manufacturing costs by optimizing stator core geometry and material usage, while allowing for flexible rotor integration and improved winding workability.
Implementation Method 1
A rotor in a motor can be rotated by an electromagnetic interaction with a stator. In some example, a coil may be wounded around the stator so that the rotor can rotate with respect to the stator as an electric current is applied to the coil.
Implementation Method 2
A permanent magnet 24 may be provided in the rotor core 21. As one example, permanent magnets 24 may be provided in an outer circumferential surface of the rotor core 21 along the circumferential direction. N-poles and S-poles of the permanent magnets 24 may be alternatively magnetized along the circumferential direction.
Data Source
AI summary
A motor including a stator includes a first stator core, and a second stator core that is independent from the first stator core and that is symmetric to the first stator core with respect to a vertical line that passes through a center of the stator. Each of the first and second stator cores includes a yoke, a center tooth that extends from a center of the yoke toward the center of the stator, and outer teeth that extend from a first end of the yoke and a second end of the yoke, respectively. The center tooth is located between the outer teeth, and a length of the outer teeth is greater than a length of the center tooth.