Split Stator Core With Support Member For Rotary Electric Machines
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Solution Overview
Problem
The conventional split core design for stator cores in rotary electric machines is complex and cumbersome, requiring additional fixing members that can hinder magnetic flux flow and complicate the manufacturing process.
Innovation Solution
A stator core design featuring first and second members with tooth parts and engaging parts, where a support member abuts against the base parts to restrict movement and enhance contact, forming a primary magnetic flux path that minimizes the influence of the support member on magnetic flux and reduces manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fixing members such as pins or screws are provided in the split core parts, then the stator core structure is stabilized and assembly is enabled, but the device complexity increases and manufacturing process becomes cumbersome
Solution Approach 1:
The support member integrates multiple functions: it supports the plurality of first members, enables engagement between first and second members, and eliminates the need for separate fixing members. By combining these functions into a single component, the invention reduces device complexity while maintaining structural stability.
Solution Approach 2:
The support member serves multiple purposes simultaneously: it acts as a support structure for the first members, provides engagement surfaces for the engaging parts, and facilitates the assembly of the split core design. This multi-functionality reduces the overall number of components needed in the stator core assembly.
2Ease of manufacture
If fixing members with different material and structure are provided in the split core parts, then assembly is enabled, but the magnetic flux flow is hindered and machine characteristics are adversely affected
Solution Approach 1:
The support member is made of the same magnetic material as the first and second members, ensuring homogeneous magnetic properties throughout the stator core assembly. This eliminates magnetic flux obstructions that would occur with dissimilar fixing members while still enabling proper assembly and structural stability.
3Loss of energy
If a split core design is adopted, then winding space factor is improved and copper loss is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The stator core is divided into multiple first members and second members that can be manufactured separately and then assembled using the support member. This segmentation enables the split core design that improves winding space factor while the simplified support member structure reduces the complexity of the assembly process.
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 design improves the characteristics of rotary electric machines by lowering magnetic resistance, reducing copper loss, and simplifying the manufacturing process while maintaining the benefits of the split core design, such as reduced copper loss due to improved winding space factor.
Implementation Method 1
a support member configured to abut against the base parts of the plurality of first members, which are arranged in the circumferential direction, so as to press the base parts of the plurality of first members from the other side toward the one side with respect to the radial direction
Implementation Method 2
the first engaging part and the second engaging part being configured such that movement of the second member toward the one side with respect to the radial direction is restricted by engagement of the second engaging part with two of the first engaging parts adjacent to each other in the circumferential direction, the engagement caused when the base parts of the plurality of first members are pressed from the other side toward the one side with respect to the radial direction
Implementation Method 3
forming a primary magnetic flux path that minimizes the influence of the support member on magnetic flux
Implementation Method 4
This design improves the characteristics of rotary electric machines by lowering magnetic resistance
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An object of the present teaching is to provide a stator core for a rotary electric machine, having a split core design with a given simple and easy structure that makes it possible to seek improvement in characteristics of the rotary electric machine with avoidance of cumbersomeness of a manufacturing process. The present teaching provides a stator core for a rotary electric machine, the stator core including: a plurality of first members arranged in a circumferential direction and each including a first tooth part, first engaging parts, and a base part, the first tooth part extending toward one side of inward and outward sides with respect to a radial direction, the first engaging parts provided on opposite sides of the first tooth part with respect to the circumferential direction, the base part provided on the other side of the inward and outward sides with respect to the radial direction; a plurality of second members arranged in the circumferential direction and each including a second tooth part and a second engaging part, the second tooth part extending toward the one side with respect to the radial direction, the second engaging part being engageable with two of the first engaging parts adjacent to each other in the circumferential direction, the plurality of second members being arranged such that the second tooth part is positioned between two adjacent first tooth parts; and a support member configured to abut against the base parts of the plurality of first members, which are arranged in the circumferential direction, so as to press the base parts of the plurality of first members from the other side toward the one side with respect to the radial direction.