Segmented Stator Lamination Stack With Tuned Holding Force
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Solution Overview
Problem
Existing methods for producing electric machine laminations struggle to maintain the cohesion of stack segments in a lamination stack with high precision and reliability, particularly in segmented stators, leading to issues with air gap and torque ripple.
Innovation Solution
The method involves using identically constructed stack segments formed from two different lamina segment groups, A and B, with A segments having radial holding structures and B segments having minimal holding force, allowing precise control of the holding force through a tool system with adjustable cutting stations and a control apparatus to ensure the holding force is within a specified range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stack segments are assembled with holding structures to maintain cohesion, then reliability of assembly is improved, but manufacturing precision deteriorates due to difficulty in ensuring high precision
Solution Approach 1:
The stator core is divided into multiple stack segments that can be assembled separately and then joined together. Each stack segment contains multiple laminations with holding structures that enable reliable assembly within the segment, while the overall segmentation allows for better manufacturing precision and handling
Solution Approach 2:
Different holding structure designs are applied to different stack segments based on their specific requirements. The holding structures include various features such as protrusions, recesses, and deformation zones that are locally optimized for each segment's assembly needs, ensuring both reliability and precision
2Stability of the object's composition
If holding structures are designed with high holding force, then assembly stability is improved, but ease of disassembly deteriorates
Solution Approach 1:
The holding structures incorporate deformation zones that allow the holding force to be dynamically adjusted. During assembly, the holding structures provide high stability, but during disassembly, the deformation zones allow controlled plastic deformation to reduce holding force, enabling easy separation without damaging the components
Solution Approach 2:
The holding force parameter can be changed by controlling the degree of plastic deformation in the holding structures. The structures are designed with specific material properties and geometric features that allow the holding force to be increased during assembly and decreased during disassembly, achieving both stability and ease of operation
Data Source
AI summary
The invention relates to a structural unit and to a method and a tool system for producing such a structural unit for an electric machine, such as a rotor or in particular a stator, with a lamination stack (1) composed of a plurality of metal laminae layered on top of one another in the direction of a longitudinal axis, which lamination stack is, in the circumferential direction, assembled from multiple stack segments (10) with lamina segments which are arranged in the circumferential direction and interlock by means of lateral holding structures. High precision of the structural unit combined with flexible adjustment of the production process to meet different requirements is achieved in that the stack segments (10) forming the lamination stack (1) are constructed in layers in the same way from at least two different lamina segment groups A (2) of identically contoured A lamina segments (20) and lamina segment groups B (3) of identically contoured B lamina segments (30), wherein the A lamina segments (20) differ from the B lamina segments (30) in their holding structures in terms of their holding force in at least the radial direction in the plane of the metal laminae.