Split Stator Insulator Assembly for Compact High-Speed Motors
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Solution Overview
Problem
Existing electric motor assemblies face challenges in reducing size while maintaining high-speed operation, as reduced size leads to increased vibration and noise due to electromagnetic force imbalance and concentricity issues, making it difficult to wind stator coils and maintain air volume.
Innovation Solution
The electric motor assembly incorporates a stator core with a ring-shaped yoke and teeth, using insulators to guide assembly and reduce friction, allowing for easier coil winding and concentricity maintenance, along with a compact design that reduces flow resistance and noise, and increases the number of rotor rotations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the electric motor assembly is reduced, then the weight and external dimensions are decreased, but the gap between teeth of the stator core is reduced making it difficult to wind the stator coil
Solution Approach 1:
The stator core is divided into a yoke part and a tooth part that can be manufactured separately and then coupled together. This segmentation allows the tooth part to be designed with sufficient gap for coil winding while maintaining the compact overall size of the motor assembly.
Solution Approach 2:
The stator core uses a split core design where the tooth part is inserted into the yoke part along the axial direction, creating a modular structure that facilitates coil winding in the radial direction while maintaining compact axial and radial dimensions.
2Volume of moving object
If the size of the electric motor assembly is reduced, then the weight and external dimensions are decreased, but electromagnetic force imbalance and vibration increase
Solution Approach 1:
The stator core is segmented into yoke and tooth parts with precise coupling mechanisms that ensure accurate concentricity. This segmentation with precision coupling maintains electromagnetic balance while enabling compact size reduction.
Solution Approach 2:
A coupling structure acts as an intermediary between the tooth part and yoke part, ensuring precise alignment and concentricity. This intermediary coupling mechanism prevents electromagnetic force imbalance and vibration during high-speed operation.
3Volume of moving object
If the size of the electric motor assembly is reduced, then the weight and external dimensions are decreased, but the air volume decreases
Solution Approach 1:
The impeller is designed with adjustable blade angles and optimized geometry to maximize air moving efficiency. This dynamic optimization allows the compact motor to maintain high air volume output despite reduced overall size.
Solution Approach 2:
The impeller parameters such as blade angle, blade number, and hub diameter are optimized to maximize air moving efficiency. These parameter changes enable the compact motor assembly to maintain high air volume despite reduced dimensions.
4Length of stationary object
If the axial size of the stator is increased to reduce radial size, then the radial dimensions are decreased, but the variation of gap between stator and rotor increases
Solution Approach 1:
The stator core is segmented into precisely coupled yoke and tooth parts that maintain consistent air gap throughout the axial length. This segmentation with precision coupling reduces gap variation despite increased axial length.
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
This configuration enables a compact motor with reduced vibration and noise, improved air volume, and increased rotor speed, while facilitating easier assembly and winding, thus addressing the challenges of size reduction and performance maintenance.
Implementation Method 1
A motor or electric motor is a device that can convert electric energy into mechanical energy. For example, an electric motor may include a stator and a rotor disposed to be rotatable relative to the stator.
Data Source
AI summary
An electric motor assembly includes a stator and a rotor configured to rotate relative to the stator. The stator includes a stator core including a yoke that has a ring shape and a plurality of teeth radially coupled to an inner surface of the yoke, a stator coil that is wound around the stator core, and an insulator disposed between the stator core and the stator coil. The insulator includes a yoke insulator that is coupled to the yoke with a first coupling tolerance defined between the yoke insulator and the plurality of tooth insulators, and a plurality of tooth insulators that are coupled to the plurality of teeth, respectively, with a second coupling tolerance defined between the yoke and the plurality of teeth. The first coupling tolerance is less than the second coupling tolerance.