Split Core Stator Support Rings for Stable Motor Assembly
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Solution Overview
Problem
Conventional motors with split core stators face issues of deformation and damage due to excessive radial force application, leading to poor electrical and mechanical performance, and difficulty in maintaining the position and posture of split cores, resulting in instability and reliability concerns.
Innovation Solution
The motor design incorporates support rings that surround the outer circumferential surfaces of split cores to support both upper and lower surfaces, minimizing deformation and damage by evenly distributing forces and stabilizing the position and posture of split cores, while also simplifying the assembly process through the exclusion of hot fitting and shared mold manufacturing for upper and lower support rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If excessive radial force is applied to tighten the split cores during support ring fitting, then the split cores are securely held in position, but the split cores deform (swell, twist, or lift) and sustain damage
Solution Approach 1:
The patent transitions from single-sided radial support to dual-sided axial support by adding upper and lower support rings. This dimensional change in support approach allows secure positioning without excessive radial force that causes deformation.
Solution Approach 2:
The patent changes the support mechanism from radial tightening force to axial support force. By applying force in the axial direction through upper and lower support rings rather than radial compression, the split cores are secured without deformation.
2Ease of manufacture
If a single support ring is used to support only the outer circumferential surfaces of split cores, then the assembly process is simpler, but the position and posture of split cores cannot be uniformly maintained
Solution Approach 1:
The patent divides the single support ring into two separate support rings (upper and lower). Each support ring independently supports one end of the split cores, enabling precise control of position and posture while maintaining assembly simplicity.
Solution Approach 2:
The patent adds axial dimension support by placing support rings at both upper and lower ends of the split cores. This transforms the support system from one-dimensional radial support to three-dimensional support, ensuring uniform position maintenance.
3Reliability
If hot fitting process is used to fit the support ring with split cores, then the support ring is securely attached, but the process complexity and manufacturing difficulty increase
Solution Approach 1:
The patent extracts and eliminates the hot fitting process from the assembly procedure. By designing support rings that can be securely attached without thermal processes, the reliability is maintained while process complexity is reduced.
Solution Approach 2:
The patent replaces the thermal-mechanical hot fitting process with a simpler mechanical assembly method. The support rings are designed to be securely attached through mechanical means alone, eliminating the need for heating and complex thermal processing.
Data Source
AI summary
The present disclosure relates to a motor including: a stator including a plurality of split cores configured to cooperatively define a ring shape; and support rings configured to surround outer circumferential surfaces of the split cores and to support upper and lower surfaces of the split cores, thereby improving stability and reliability.