Split Stator Core for High-Speed Motor Winding
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Solution Overview
Problem
High-speed electric motors with a large number of magnetic poles and teeth experience deteriorated controllability due to roughened current waveforms, leading to inefficiencies and difficulty in winding stator coils effectively.
Innovation Solution
An electric motor design featuring a stator with four split cores, each comprising a yoke and tooth, where the angle between the tooth and yoke side surfaces is between 90 degrees and 180 degrees, allowing easy wire winding and improved controllability, using amorphous metal for the stator core to reduce iron loss, and a single-phase inverter for reduced switching losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the number of magnetic poles and teeth is increased, then motor efficiency is improved, but controllability deteriorates due to roughened current waveforms
Solution Approach 1:
The stator core is divided into multiple split cores (e.g., 12 core elements) to facilitate wire winding while maintaining a manageable number of teeth (e.g., 4 teeth per split core). This segmentation allows the motor to achieve high efficiency through increased magnetic poles and teeth without compromising controllability, as the split core structure enables precise wire placement and high coil density even with fewer teeth per core.
Solution Approach 2:
Different regions of the stator are optimized for different functions: the split core structure with specific geometric parameters (angles θ1 and θ2 between 90-180 degrees) optimizes the winding region for ease of wire insertion and coil density, while the overall stator design with controlled number of teeth maintains good controllability. This local optimization allows simultaneous achievement of high efficiency and good controllability.
2Loss of energy
If the number of magnetic poles and teeth is increased to enhance motor efficiency, then wire winding becomes more difficult, but controllability is improved
Solution Approach 1:
The stator core is divided into multiple split cores (e.g., 12 core elements forming 4 teeth) to facilitate wire winding. Each split core can be independently wound with stator coils, making the winding process much easier compared to winding around a complete stator with many teeth. This segmentation maintains ease of manufacture while achieving high motor efficiency through increased magnetic poles and teeth.
Solution Approach 2:
The stator is pre-divided into split cores before the wire winding process. This preliminary segmentation creates accessible winding regions with optimized geometric parameters (angles θ1 and θ2 between 90-180 degrees), making wire insertion and coil formation easier before assembly into the complete stator structure.
3Reliability
If the number of teeth is reduced to improve controllability, then stator coil density decreases, but wire winding becomes easier
Solution Approach 1:
The stator core is divided into multiple split cores (e.g., 12 core elements forming 4 teeth), where each split core contains multiple core elements that can be independently wound. This segmentation allows high coil density to be achieved within each split core while maintaining a small total number of teeth (4) for good controllability. The multiple core elements per tooth contribute to high overall coil density.
Solution Approach 2:
Multiple core elements are nested within each tooth structure of the split cores. This nesting arrangement allows high coil density by packing multiple winding regions within the space of fewer teeth, achieving both high stator coil density and good controllability simultaneously.
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 design enhances controllability and efficiency by reducing electrical frequency and switching losses, facilitating easier wire winding and increased stator coil density, while maintaining a compact motor size.
Implementation Method 1
using amorphous metal for the stator core to reduce iron loss
Implementation Method 2
an electric motor includes: a stator (2) including four split cores (20); and a rotor (3) disposed inside the stator (2) and having four magnetic poles
Data Source
AI summary
An electric motor includes a stator including four split cores, and a rotor having four magnetic poles. Each of the split cores includes a yoke and a tooth. An angle θ1 [degree] formed by a side surface of the tooth and a side surface of the yoke on an inner side in a radial direction of the stator satisfies 90 degrees ≤θ1<180 degrees.