Slotless Motor Armature Insulator With Soft-Magnetic Members for Torque
Solution Overview
Problem
The existing slot-less motors do not effectively contribute to torque generation, leaving room for improvement without increasing motor size.
Innovation Solution
An armature and motor design featuring an annular armature core with wound conductive coils and an insulator made of insulating material with soft-magnetic members, which enhances torque generation without increasing size by optimizing coil configuration and magnetic flux utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the insulator is made of conventional insulating material only, then electrical insulation is provided, but torque generation is insufficient
Solution Approach 1:
The insulator is constructed as a composite material combining insulating material with soft-magnetic members dispersed within it. This composite structure enables the insulator to simultaneously provide electrical insulation through the insulating material and enhance magnetic flux utilization through the soft-magnetic members, thereby improving torque generation without increasing motor size.
2Force
If the motor size is increased to improve torque, then torque output increases, but compactness is lost
Solution Approach 1:
The invention changes the material parameters of the insulator by incorporating soft-magnetic members with high magnetic permeability. This parameter change allows the insulator to more effectively conduct and utilize magnetic flux, thereby improving torque generation within the same motor volume without requiring size increase.
3Force
If coils are wound with larger span to improve performance, then manufacturing complexity increases, but torque improves
Solution Approach 1:
The soft-magnetic members in the insulator act as intermediaries that guide and concentrate magnetic flux between the coils and armature core. This intermediary function allows for more effective magnetic coupling even with conventional coil configurations, reducing the need for complex wide-span coil arrangements while maintaining improved torque performance.
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 torque output while maintaining a compact size, reducing electrical resistance and copper loss, and enhancing heat dissipation, leading to a more efficient and powerful motor.
Implementation Method 1
one or more soft-magnetic members each being comprised of a soft-magnetic material. The one or more soft-magnetic members are contained in the base
Implementation Method 2
a plurality of coils arranged along the armature core. Each of the coils is a wound conductive winding
Implementation Method 3
The armature includes an insulator arranged between the stator core and the coils. The insulator includes a base comprised of an insulating material
Data Source
AI summary
A stator includes an armature core having an annular shape, coils, and an insulator. The coils are arranged along the armature core. Each of the coils is a wound conductive winding. Each of the coils includes a pair of facing portions disposed to be aligned in a circumferential direction with a predetermined interval therebetween. The first and second facing portions of each of the coils constitute intermediate portions of the corresponding one of the coils. Each of the coils includes a pair of first and second coil end portions that link the facing portions to each other. The insulator is arranged between the stator core and the coils. The insulator includes a base comprised of an insulating material, and one or more soft-magnetic members each being comprised of a soft-magnetic material, the one or more soft-magnetic members being contained in the base.