Segmented Stator Assembly with Detachable Magnetic Powder Teeth
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Solution Overview
Problem
Conventional stator assemblies face issues with production costs and potential damage to coils due to the need for deformation when using rectangular wire coils, which are pre-formed and inserted into slots, leading to potential premature stator failure.
Innovation Solution
A stator assembly with a cylindrical core body featuring longitudinal grooves and detachable teeth made of magnetic powder material, allowing pre-formed coils to be positioned between teeth and wrapped with a flexible layer, which are then inserted into the grooves, reducing the need for deformation and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-formed rectangular wire coils are inserted into stator slots, then coil assembly is simplified, but the coils must be deformed which increases production costs and may damage the coils
Solution Approach 1:
The stator is segmented into modular components: a core body with grooves and separate teeth that can be independently assembled. This segmentation allows pre-formed coils to be positioned between teeth without forced insertion into tight slots, eliminating deformation while simplifying assembly.
Solution Approach 2:
The wrapping layer acts as an intermediary element that facilitates coil positioning and secures coils between the teeth. This intermediary component enables easy coil installation without direct forced insertion into the core, preventing damage while maintaining assembly simplicity.
2Strength
If conventional stator assemblies with slots are used, then structural integrity is maintained, but coil insertion requires deformation increasing production complexity
Solution Approach 1:
By dividing the stator into core body and separate teeth components, the invention maintains structural integrity through the wrapping layer that secures all parts together, while dramatically simplifying the assembly process by allowing coils to be positioned between teeth before final assembly.
Solution Approach 2:
Coils are preliminarily positioned between the teeth before the teeth are assembled to the core body. This preliminary positioning eliminates the need for post-assembly coil insertion and deformation, reducing production complexity while maintaining structural integrity.
3Productivity
If teeth are made detachable and assembled into grooves, then assembly efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The wrapping layer functions as a flexible element that accommodates minor variations in tooth and groove dimensions, allowing efficient assembly without requiring extremely tight manufacturing tolerances while still securing the modular components together.
Solution Approach 2:
The segmented design with discrete teeth and grooves allows for standardized manufacturing of each component within reasonable tolerances, with the wrapping layer providing the final positioning and securing function that compensates for accumulated tolerances.
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 solution reduces production costs and minimizes coil damage by allowing for easier and more efficient assembly of the stator, improving the reliability and longevity of the electric machine.
Implementation Method 1
coils are so mounted to the cylindrical body as to produce an outwardly projecting magnetic field that interacts with the externally provided rotor
Data Source
AI summary
A stator assembly is provided with detachable teeth that are made of magnetic powder material. The teeth are so configured and sized as to be interconnected to a core body of the stator with pre-formed coils that are positioned between adjacent teeth.