Segmented Stator Tooth Coupling for Tolerance and Vibration Control
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Solution Overview
Problem
Existing segmented stator lamination technologies face challenges in efficiently connecting and calibrating stator or rotor segments due to variations in segment-to-segment distances, leading to vibrations and increased manufacturing complexity.
Innovation Solution
A modular segmented stator design featuring individual teeth with groove-shaped fastening contours and press-fit connections, allowing for efficient assembly and calibration, with optional overmolding for insulation and wire accommodation, and environmentally friendly impregnation to minimize material waste and enhance vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If through bolts with nuts are used to connect stator segments, then the segments can be securely connected, but the manufacturing complexity increases due to the need for shims of different sizes to compensate for tolerance variations
Solution Approach 1:
The patent extracts the complexity of tolerance compensation by removing the shim component entirely. Instead of using shims of different sizes to compensate for segment tolerance variations, the invention uses a connection element with a deformationable connection portion that automatically adapts to tolerance variations through elastic deformation, thereby eliminating the need for multiple shim sizes and reducing assembly complexity
Solution Approach 2:
The patent applies parameter changes by utilizing the elastic deformation capability of the connection portion. The connection portion is designed to deform elastically within a specific range to compensate for tolerance variations in segment dimensions. This allows the connection to maintain stability without requiring precise pre-adjustment through shims, thereby simplifying the assembly process while ensuring reliable connection
2Manufacturing precision
If shims of different sizes are used to compensate for segment-to-segment distance variations, then the segment spacing can be calibrated, but the manufacturing process becomes more complicated and time-consuming
Solution Approach 1:
The connection portion serves itself by automatically compensating for spacing variations through elastic deformation. The deformationable connection portion inherently adjusts to accommodate tolerance variations in segment dimensions, eliminating the need for operators to manually select and install different sized shims. This self-adjusting mechanism maintains precise segment spacing while significantly improving assembly efficiency
Solution Approach 2:
The connection element is pre-designed with a deformationable connection portion that has built-in elastic compliance. This preliminary design allows the connection to automatically absorb spacing variations without requiring any preliminary adjustment actions during assembly, such as selecting appropriate shims. The tolerance compensation is built into the connection element itself, streamlining the manufacturing process
3Device complexity
If a one-piece stator design is used, then the structure is simple, but material consumption and punching waste increase significantly
Solution Approach 1:
The patent applies segmentation by dividing the stator into multiple separable segments that can be manufactured independently and then connected using connection elements. This segmentation allows for optimized nesting and arrangement of individual stator segments during the punching process, reducing material waste compared to a one-piece design. The segmented approach maintains structural integrity through the connection elements while enabling more efficient material utilization
4Strength
If segments are connected with rigid fastening, then the connection is strong, but vibrations increase and fatigue occurs due to movement between segments
Solution Approach 1:
The deformationable connection portion acts as a beforehand cushioning element that absorbs vibrations and movement between segments. By designing the connection portion with elastic deformation capability, the patent creates a built-in damping mechanism that prevents rigid transmission of vibrations between segments, thereby reducing fatigue and harmful vibrations while maintaining connection strength
Solution Approach 2:
The patent applies dynamics by transitioning from a rigid static connection to a dynamic elastic connection. The connection portion is designed to deform elastically in response to vibrations and movements between segments, allowing the connection to adapt dynamically to operational conditions. This dynamic capability maintains strong connection while accommodating vibrations, preventing the fatigue that would occur with rigid fastening
Data Source
AI summary
A segmented stator has a plurality of individual teeth (12) connected to one another in the direction of rotation. Each individual tooth (12) has a connecting portion (17) to produce a nonpositive mechanical connection with at least one directly adjacent individual tooth (12). The respective connecting portion (17) has a groove-shaped fastening contour (18, 18a, 19, 19a), at least on one connecting side (17a, 17b), facing toward the directly adjacent individual tooth (12). The fastening contour (18, 18a, 19, 19a) of an adjacent individual tooth (12) can be connected to its connecting portion (17), such that a nonpositive connection is produced which ensures a magnetic flux.