Stator Assembly Teeth with Arc-Like Neck for Motor Efficiency
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Solution Overview
Problem
Conventional stator assemblies in direct circuit brushless motors are inefficient and costly due to the shape of the stator core teeth, which affects the distribution of the magnetic field and the efficiency of the motor.
Innovation Solution
A stator assembly with a stator core formed by stacked silicon steel sheets, featuring teeth with a neck that includes a first and second stacking portion, first and second plane portions, and a winding support structure that allows for a reduced perimeter and length of the winding, reducing copper consumption and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conventional stator core teeth shape is used, then the structure is simple to manufacture, but the magnetic field distribution is poor and motor efficiency is low
Solution Approach 1:
The tooth is segmented into multiple functional portions: a first stacking portion, a second stacking portion, a first plane portion, and a second plane portion. Each portion serves a specific function in optimizing magnetic field distribution and winding support, thereby improving motor efficiency while maintaining manufacturability through modular design
Solution Approach 2:
The patent introduces arc-like shapes in the stacking portions and plane portions, transitioning from conventional straight-edged teeth to curved geometries. This dimensional change optimizes the magnetic field distribution and winding fit, improving efficiency without significantly complicating the manufacturing process
2Loss of substance
If the conventional tooth shape is used, then the manufacturing process is simple, but the winding perimeter is large and copper consumption is high
Solution Approach 1:
The first stacking portion and second stacking portion are designed with arc-like shapes instead of straight edges. This curvature reduces the overall perimeter of the tooth while maintaining the necessary magnetic path length, thereby reducing copper consumption in the windings without significantly increasing manufacturing complexity
Solution Approach 2:
The patent optimizes the dimensions and ratios of different tooth portions, specifically controlling the relationship between the arc radii and the overall tooth dimensions. These parameter changes achieve perimeter reduction and copper savings while keeping the manufacturing process feasible
3Productivity
If the conventional tooth shape is used, then the structure is simple, but the winding support is insufficient and efficiency is low
Solution Approach 1:
The neck structure is divided into distinct stacking portions and plane portions, each optimized for specific functions: supporting the winding, providing mechanical strength, and facilitating assembly. This segmentation improves winding support and efficiency while maintaining reasonable manufacturing complexity
Solution Approach 2:
The neck structure employs asymmetric design with different stacking portions having different geometries tailored to their specific functional requirements. This asymmetric configuration optimizes winding support and magnetic field distribution, improving efficiency without excessive manufacturing complexity
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 stator assembly improves motor efficiency and power by reducing the perimeter of the winding and copper consumption while lowering manufacturing costs through the use of silicon steel sheets and an arc-like shape in the neck, facilitating smoother winding and assembly processes.
Implementation Method 1
The stator generates a magnetic field which changes regularly after the winding is energized, and the rotor includes a permanent magnetic material, and the rotor may be rotated in the magnetic field generated by the stator
Data Source
AI summary
A stator assembly includes a stator core. The stator core includes a yoke and teeth. Each of the teeth includes a neck and a tip. The neck includes a first stacking portion, a second stacking portion, a first plane and a second plane. The first stacking portion and the second stacking portion are arranged opposite to each other, and the first plane and the second plane are arranged opposite to each other. The first stacking portion and the second stacking portion are formed by stacking silicone steel sheets of the neck, and the first plane and the second plane are outer surfaces of silicone steel sheets at two terminal ends of the neck in a stacking direction.