Split Stator Core Assembly for Compact Charging Motors
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Solution Overview
Problem
Existing electric engines for charging devices face challenges in manufacturing complexity, efficiency losses, and high costs due to limited installation space and the need for complex assembly of stator components, particularly in high-speed applications like eTurbochargers and e-chargers.
Innovation Solution
A stator arrangement for electric engines is divided into an outer and inner stator core, allowing for a larger inner diameter to accommodate bearing units, enabling simpler assembly, non-destructive replacement, and optimized cooling, while reducing pulsation losses and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a one-piece stator core design is used, then the structural integrity is improved, but the assembly complexity and manufacturing difficulty increase due to limited installation space
Solution Approach 1:
The stator core is divided into two separate parts: an outer stator core and an inner stator core. The outer stator core can be assembled first with a larger inner diameter to accommodate bearing units, and the inner stator core is then inserted into the outer stator core. This segmentation resolves the contradiction by enabling simpler assembly while maintaining structural integrity through the combined design of both cores.
2Volume of moving object
If the inner diameter is reduced to accommodate the rotor, then the installation space is optimized, but the bearing unit replacement becomes difficult and destructive
Solution Approach 1:
By dividing the stator core into outer and inner parts, the outer stator core provides a sufficient inner diameter for bearing unit installation and removal, while the inner stator core is positioned to accommodate the rotor. This allows non-destructive bearing replacement while maintaining optimized installation space.
Solution Approach 2:
The inner stator core acts as an intermediary element that can be temporarily removed to allow bearing unit access, and then reinserted to restore the optimized installation space configuration.
3Ease of manufacture
If the stator core is made as a single piece, then the manufacturing process is simplified, but the production costs and assembly time increase
Solution Approach 1:
The stator core is segmented into outer and inner parts that can be manufactured separately using standardized processes, then quickly assembled together. This segmentation enables parallel manufacturing of components and reduces overall assembly time, improving productivity while keeping manufacturing processes simple and cost-effective.
4Volume of moving object
If the stator core design is optimized for compactness, then the installation space is improved, but the cooling efficiency and heat dissipation are reduced
Solution Approach 1:
The segmented stator core design with the inner stator core positioned within the outer stator core creates channels and pathways that facilitate heat dissipation. The configuration allows for optimized thermal management while maintaining compact installation space, as the inner core can be positioned to maximize cooling efficiency without increasing overall volume.
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 divided stator core design facilitates easier assembly, reduces production costs, and enhances efficiency by allowing direct encapsulation in the housing, improving heat dissipation and reducing assembly time, while maintaining performance across varying rotor sizes.
Implementation Method 1
The inner stator core is designed to lengthen a magnetic flux path in a radial direction during operation
Implementation Method 2
The outer stator core comprises electrical windings or is wound with electrical windings
Data Source
AI summary
A stator arrangement for an electric engine having an inner rotor. The present invention furthermore relates to an electric engine for a charging device, in particular for an internal combustion engine or a fuel cell, having such a stator arrangement. The stator arrangement comprises an outer stator core with electrical windings, and a separate inner stator core, which is arranged inside the outer stator core and is designed to receive the rotor. The outer stator core defines a first inner diameter, which is dimensioned in such a way that a bearing unit of the electric engine can be guided through the outer stator core. An outer diameter of the inner stator core substantially corresponds to the first inner diameter, wherein the inner stator core is designed to extend a magnetic flux in the radial direction during operation. The invention furthermore relates to a method for producing the electric engine.