Spiral Laminated Rotor Core for Rotary Electric Machines
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Solution Overview
Problem
The existing laminated core manufacturing processes for rotary electric machines are cumbersome and time-consuming, leading to increased costs due to the need for staggered arrangement and complex connecting processes, which result in higher manufacturing time and cost.
Innovation Solution
A laminated core design featuring arc-shaped unit cores with through-holes and protruding/recessed portions, wound and laminated in a spiral shape, allowing for efficient axial lamination and connection, reducing the lamination time and enhancing mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If arc-shaped sheet parts are arranged in staggered manner with predetermined angle, then the rotor core is unified and prevented from separating, but the laminating process becomes troublesome and laminating time increases
Solution Approach 1:
The rotor core is divided into multiple arc-shaped sheet parts that are laminated in a specific pattern. Each sheet part is a segment of the complete rotor core, and by laminating multiple segments in sequence with proper staggering, the core achieves unity while maintaining efficient manufacturing. The segmentation allows for standardized production of individual sheets that are then assembled into the complete core structure.
Solution Approach 2:
The invention transitions from arranging sheets in a simple planar staggered pattern to a three-dimensional lamination structure where sheets are stacked with specific angular offsets. By introducing the axial dimension and controlling the radial position of contacting portions across multiple layers, the design achieves both structural unity and manufacturing efficiency. The contacting portions are positioned at different radial distances from the rotation axis in different layers, creating a robust three-dimensional interlocking structure.
2Reliability
If connecting process in axial direction is required for connection between recess and projection portions, then the core structure is unified, but the laminating process becomes more complex
Solution Approach 1:
The invention combines the lamination process with the connection function by designing the sheet parts to inherently interlock through their geometric features. The protruding and recessed portions are integrated into the sheet structure itself, allowing adjacent sheets to connect automatically during lamination without requiring separate connecting operations. This merging of structural and connectional functions simplifies the overall manufacturing process while ensuring core unity.
Solution Approach 2:
The sheet parts are designed with self-connecting features where the protruding portions of one sheet automatically fit into the recessed portions of adjacent sheets during the lamination process. This self-service mechanism eliminates the need for external connecting elements or additional connection steps, as the structure connects itself through its own geometric features during assembly.
3Reliability
If contacting portions between arc-shaped sheet parts are displaced in circumferential direction among layers, then the rotor core is prevented from separating, but manufacturing cost increases
Solution Approach 1:
The invention systematically varies the radial position parameter of contacting portions across different layers while maintaining a regular patterning scheme. By controlling the radial distance from the rotation axis according to a defined pattern, the design achieves optimal mechanical interlocking and centrifugal force resistance. This parameter-controlled approach allows for standardized manufacturing processes and predictable material usage, reducing overall manufacturing cost while ensuring core integrity.
Data Source
AI summary
A laminated core having a first number of magnetic poles, the first number being a natural number divided by two, of a rotary electric machine, includes a plurality of arc-shaped unit cores each having a second number of magnetic poles, the second number being a natural number except for an aliquot part of the first number. The unit cores are wound and laminated a predetermined number of times in a circumferential direction into a spiral shape in such a manner that an axial lamination amount of the unit cores is obtained by an equation of X=θ*t/360, X being the axial lamination amount, θ being a winding angle of the unit cores, and t being a thickness of the unit core. The unit cores are adjacent to each other in the circumferential direction connected to each other at a part of an outer circumference thereof.