Segmented Stator Laminations with GOES Teeth
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Solution Overview
Problem
The production of stator laminations for electric machines is wasteful and does not optimize performance, leading to inefficiencies in material usage and electrical performance.
Innovation Solution
A stator core design featuring a stack of laminations with grain-oriented electrical steel (GOES) tooth segments and non-grain oriented electrical steel (NGOES) yoke segments, interconnected with staggered interlock structures to enhance magnetic flux and reduce material waste, along with a method of fabricating these laminations using an expandable arbor and sleeve to form a compact, efficient stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional stator laminations are used, then eddy current is reduced and stator core is cooled, but material waste increases and electrical performance is not optimized
Solution Approach 1:
The stator core is divided into multiple individual laminations stacked together, with each lamination being a separate piece that can be independently manufactured and optimized. This segmentation allows for reduced eddy current losses while enabling more efficient material utilization through precise cutting and stacking arrangements.
Solution Approach 2:
Different regions of the stator core use laminations with different grain orientations - GOES material with radial grain orientation in tooth segments for optimized magnetic flux, and NGOES material in yoke segments. This local quality differentiation optimizes electrical performance in each specific region while reducing overall material waste.
2Loss of energy
If traditional stator laminations are used, then eddy current is reduced, but electrical performance is not optimized
Solution Approach 1:
The patent applies different material properties to different regions: GOES material with radial grain orientation in tooth segments for optimized magnetic flux density, and NGOES material in yoke segments. This local quality differentiation simultaneously reduces eddy current losses and optimizes electrical performance by matching material properties to functional requirements in each region.
Solution Approach 2:
The stator core uses a composite construction combining GOES and NGOES materials in specific configurations. This composite approach allows each material type to contribute its strengths - GOES for reduced hysteresis loss and optimized flux in teeth, and NGOES for structural integrity and flux distribution in the yoke - achieving superior overall electrical performance.
3Loss of substance
If segmented lamination construction is used, then material waste is reduced and electrical performance is optimized, but device complexity increases
Solution Approach 1:
The stator core is divided into multiple individual laminations stacked together, with each lamination being a separate piece that can be independently manufactured and optimized. This segmentation allows for reduced eddy current losses while enabling more efficient material utilization through precise cutting and stacking arrangements.
Solution Approach 2:
Different regions of the stator core use laminations with different grain orientations - GOES material with radial grain orientation in tooth segments for optimized magnetic flux, and NGOES material in yoke segments. This local quality differentiation optimizes electrical performance in each specific region while reducing overall material waste.
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
The design improves electrical performance by optimizing magnetic flux and reduces material waste through segmented lamination construction and efficient fabrication, leading to enhanced efficiency and cost-effectiveness in stator core production.
Implementation Method 1
each tooth segment in the plurality of tooth segments has a tooth grain orientation in a radial direction from the central axis
Implementation Method 2
the use of laminations reduces hysteresis loss. Specifically, lamination plates have narrow hysteresis loops, requiring less energy to magnetize and demagnetize the core
Implementation Method 3
the electromagnetic field of a stator core generates a voltage, called an eddy current, that may result in power loss and diminished performance. Stator laminations reduce eddy current by insulating the stator core. Specifically, thin silicon steel plates that are stacked on top of one another around the center prevent eddy current flow
Implementation Method 4
A solid unitary stator core would heat up with the eddy current. Therefore, reduction of the eddy current also prevents overheating of the stator core
Data Source
AI summary
Stator cores and methods for fabricating stator cores are provided. An exemplary stator core includes a stack of laminations. Each lamination in the stack of laminations comprises a yoke and a plurality of tooth segments fixed to the yoke.