Stator, motor, compressor, and refrigerating and air-conditioning apparatus
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Solution Overview
Problem
Conventional stators with right-angled corners in the stator core suffer from winding disorder and reduced winding density due to long magnetic paths and high magnetic flux density, leading to iron loss and decreased motor efficiency, while curved surfaces at corners make it difficult to align windings and increase density.
Innovation Solution
A stator design featuring split core parts with a curved surface connection between the yoke and tooth parts, using a coil bobbin with protruding parts that extend beyond the curved surface, providing adequate insulation and supporting the winding to prevent disorder and increase density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the stator core has corners forming right angles between the inner circumferential surfaces of the yoke part and the side surfaces of the tooth parts, then the density of the winding can be increased, but the magnetic path length increases and magnetic flux density becomes large, causing iron loss and reducing motor efficiency
Solution Approach 1:
The patent applies curvature to the corner portions of the stator core by providing insulators with curved surface shapes that match the corner geometry. This allows the winding to be properly aligned and densely packed around the curved corners, while the insulator's curved surface prevents the magnetic path from extending unnecessarily along the corner, thereby reducing iron loss while maintaining high winding density.
2Loss of energy
If the stator core has curved surfaces at the corners between the inner circumferential surfaces of the yoke part and the side surfaces of the tooth parts, then the magnetic path length is reduced and iron loss decreases, but the winding alignment becomes difficult and winding density cannot be increased
Solution Approach 1:
The patent introduces insulators as intermediary components that bridge the gap between the curved corner surfaces and the winding. The insulators are specifically shaped with curved surfaces that conform to the corner geometry, serving as a mediator that enables proper winding alignment on curved surfaces while maintaining the beneficial curved geometry for reducing iron loss.
Solution Approach 2:
The insulators are designed with curved surface shapes that match the curved corners of the stator core. This curvature allows the winding to be properly aligned and densely packed around the curved corners, solving the alignment difficulty while maintaining the curved geometry's advantage of reducing magnetic path length and iron loss.
3Reliability
If insulators are provided on the stator core, then the insulation performance is improved, but the space available for winding is reduced, making it difficult to increase winding density
Solution Approach 1:
The patent applies insulators selectively only at the corner portions of the stator core rather than uniformly across the entire core surface. This localized placement provides necessary insulation at the critical corner areas where insulation is most needed, while minimizing the space occupied by insulators and leaving maximum space available for winding in the non-corner regions, thereby maintaining high winding density.
Data Source
AI summary
A stator includes a winding and a plurality of split core parts arranged annularly in a circumferential direction around an axis line. Each of the plurality of split core parts includes a yoke part, a tooth part, a connection part including a curved surface, and a first insulator provided on an end part of the tooth part. The first insulator includes a first protruding part protruding beyond the curved surface.