Segmented Stator Core Positioning for Torque Stability
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Solution Overview
Problem
The existing permanent magnet synchronous motors face challenges with unstable output parameters due to the inconvenience of machining the stator core and lack of positioning structure, leading to torque fluctuations and low reliability in speed and position control.
Innovation Solution
The stator core is designed as multiple spliced core blocks without tooth sockets for coil embedding, allowing for easier machining and precise positioning using raised parts and matching grooves in the housing, ensuring stable torque output and high-precision control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator core is designed as an integral structure with tooth sockets for embedding coil windings, then the coil winding can be securely mounted, but the core becomes inconvenient to machine and the output torque fluctuates
Solution Approach 1:
The stator core is divided into multiple core blocks that are spliced together to form the complete core structure. Each core block can be independently machined without tooth sockets, simplifying the machining process. The core blocks are then assembled using connecting pieces with positioning structures (raised parts and grooves) to form the integral core functionality, resolving the contradiction between machining convenience and structural integrity.
2Manufacturing precision
If the stator core is designed as an integral structure with tooth sockets, then the structural strength is maintained, but high-precision control of speed and position is influenced due to torque fluctuations
Solution Approach 1:
The core is segmented into multiple blocks without tooth sockets, eliminating the source of torque fluctuations that affect precision control. The segmentation simplifies each individual component while the assembly mechanism (connecting pieces with positioning structures) restores the functional integrity, thereby improving speed and position control precision without excessive complexity.
Solution Approach 2:
The tooth sockets are extracted from the core structure and relocated to the connecting pieces. This removal of tooth sockets from the core eliminates the harmful effect on torque smoothness while the connecting pieces with raised parts and grooves provide the necessary mechanical connection and positioning functionality.
3Reliability
If no positioning structure is provided between the core and housing, then the manufacturing process is simplified, but the relative positions of the core and rotor easily deviate during rotation, reducing reliability
Solution Approach 1:
The positioning function is extracted from the traditional core-housing interface and implemented through raised parts on the core blocks that engage with corresponding grooves in the housing. This targeted positioning approach provides stable output parameters while minimizing unnecessary structural complexity.
Solution Approach 2:
The connecting pieces serve as intermediaries between the core blocks and the housing, incorporating both the mechanical connection function and the positioning function through raised parts. This intermediary structure ensures proper positioning and fixation without requiring complex positioning mechanisms in the housing itself.
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 the stability and reliability of the motor by preventing core deviation and maintaining sinusoidal magnetic induction, enabling stable output parameters and high-precision speed and position control.
Implementation Method 1
the core blocks are provided with raised parts, and grooves matched with and pressing against the raised parts are formed in the inner wall of the housing to realize positioning and fixation of the core
Implementation Method 2
a stator of a permanent magnet synchronous motor generally includes a core for magnetic conduction
Data Source
AI summary
A permanent magnet synchronous motor is provided in the present disclosure. The permanent magnet synchronous motor includes a housing as well as a stator and a rotor received in the housing, the stator surrounding the rotor, wherein the stator comprises a core which surrounds the rotor and is annular and a plurality of coils wound on the core, the plurality of coils are disposed at intervals and distributed in an annular array, the core is composed of a plurality of core blocks spliced with each other, the core block comprises a raised part on the outer wall, and grooves matched with the raised parts in shape and used for positioning the raised parts are formed in the inner wall of the housing.