Split-Tooth Stator Coupling Structure for Low Core Loss
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Solution Overview
Problem
Existing motor stators with split teeth face challenges in maintaining rigidity and efficiency due to increased core loss and magnetic flux variation, especially in small motors with thin back yokes, where adhesive force is crucial but difficult to achieve without compromising output.
Innovation Solution
A stator design with a back yoke having recessed grooves and split teeth featuring a coupling portion that extends radially and has a bonding area with a specific width ratio, optimizing the bonding surface area and minimizing magnetic flux leakage, thereby enhancing adhesive force and motor efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the contact area on split teeth is increased to maintain rigidity through adhesive force, then adhesive force is improved, but core loss increases and motor output decreases
Solution Approach 1:
The patent applies local quality by creating a groove with varying width along its length, where the width is greater at the opening than at the bottom. This allows the bonding surface area to be increased locally at the opening for stronger adhesive force, while the narrower bottom portion minimizes the overall volume of the back yoke material, reducing core loss. The groove width transitions optimally between these regions.
Solution Approach 2:
The patent transitions from considering only the cross-sectional area of the groove to incorporating the third dimension (length along the groove) by creating a tapered groove profile. This dimensional change allows the bonding surface to extend further along the groove length while maintaining a smaller overall material volume, thus increasing adhesive force without proportionally increasing core loss.
2Reliability
If the thickness of the back yoke is increased to reduce magnetic flux leakage, then magnetic flux density distribution is improved, but the motor size and weight increase
Solution Approach 1:
The patent applies local quality by concentrating the back yoke material where it is most needed for magnetic flux containment. The groove is positioned and dimensioned to provide sufficient material thickness in critical areas for magnetic flux density distribution, while removing unnecessary material in non-critical areas, thus maintaining reliability without increasing overall weight.
3Strength
If a complex bonding portion shape is used to increase adhesive force, then adhesive force is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent segments the bonding portion into distinct functional zones: a wider opening region for maximum adhesive bonding, a tapered transition region, and a narrower bottom region. This segmentation allows each zone to be optimized for its specific function while maintaining overall manufacturability through a systematic geometric progression rather than an arbitrary complex shape.
Data Source
AI summary
The present disclosure relates to a stator which prevents motor efficiency from deteriorating while increasing divided contact areas of divided teeth. According to the present disclosure, provided is a stator characterized by comprising a back yoke having a certain thickness in the radial direction, and divided teeth coupled to the back yoke, wherein: the back yoke includes recessed grooves into which the divided teeth fit; the divided teeth include a winding portion forming a section on which a coil is wound and a coupling portion extending from the winding portion and fitting into the grooves; and the length of the back yoke in the radial direction at the coupling portion is greater than half the thickness of the back yoke.