Axial Flux Stator Assembly Without Air-Gap Plastic for High Torque
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Solution Overview
Problem
Conventional stators for axial flux machines have limited torque transmission capabilities due to adhesive connections and the presence of plastic components in the air gap, which reduce torque transmission and require complex assembly processes.
Innovation Solution
A stator design featuring a support structure with coaxially spaced support disks, clamping rings, and a stator outer shell, which securely clamps laminated cores and eliminates the need for plastic components, allowing for high torque transmission through force-fitting connections and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bonds are used to connect the plastic component to the top side, then assembly is simplified, but torque transmission capability is limited by adhesive strength
Solution Approach 1:
The patent replaces the adhesive bonding system with a mechanical clamping system. The clamping ring with clamping elements provides direct mechanical fixation between the stator core and top side, eliminating reliance on adhesive bonds and enabling higher torque transmission through friction and mechanical interlocking.
Solution Approach 2:
The patent changes the connection mechanism from chemical bonding (adhesive) to mechanical bonding (clamping). The clamping elements can be adjusted to provide optimal clamping force, and the friction coefficient between contact surfaces can be optimized to achieve high torque transmission capability.
2Reliability
If a plastic component is placed in the air gap for coil anchoring, then coil units are secured, but torque transmission is further reduced due to the plastic component's presence
Solution Approach 1:
The patent removes the plastic component from the air gap entirely. Instead, coil units are anchored directly to the stator core using clamping elements that apply radial clamping force, eliminating the torque-transmitting obstacle while maintaining secure coil anchoring.
Solution Approach 2:
The patent introduces clamping elements as intermediaries between the coil units and the stator core. These clamping elements provide secure anchoring through mechanical interlocking and friction, replacing the need for a plastic component while enabling direct torque transmission from the air gap to the stator core.
3Ease of manufacture
If conventional adhesive bonding is used for assembling stator components, then assembly process is simple, but disassembly and reassembly become difficult
Solution Approach 1:
The patent creates a dynamic clamping system where clamping elements can be actively adjusted or released. The clamping force can be increased during operation to secure components, but the system allows for controlled release during maintenance, enabling both secure assembly and easy disassembly that adhesive bonds cannot provide.
Data Source
AI summary
A stator for an electric axial flux machine includes a support structure with two support discs having star extensions, a rotor shaft bearing, and coil units each arranged between two pairs of star extensions following one another in the circumferential direction and are thereby fixed in the circumferential direction. Respective end portions of each laminated core of the coil units project beyond the support structure in the axial direction. Radially external fixing ends of the star extensions project radially outwards beyond the coil units. The coil units are clamped radially in the direction of the rotor shaft bearing by a clamping ring. A stator outer shell is arranged between the support discs and radially surrounds the coil units in the circumferential direction, the stator outer shell being attached to the fixing ends of the star extensions for conjoint rotation.