Electric Motor Stator Axial Bracing via Oblique Coil Former Alignment
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Solution Overview
Problem
The existing stator design for electric motors lacks adequate axial security during assembly, leading to incorrect positioning and potential detachment of stator laminates, and is prone to air gaps due to tolerances, which negatively impact magnetic flux guidance.
Innovation Solution
The stator design involves placing coil formers obliquely on coil former holders and aligning them in a final position to achieve axial bracing of stator laminates, using a pivoting stud and flexible frame internal faces with crushing ribs for tolerance compensation and clamping, allowing a high clamping force with minimal alignment force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coil formers are plugged onto the base body with cross-sectional constrictions for latching, then initial assembly is enabled, but axial security is insufficient leading to incorrect positioning and detachment of stator laminates
Solution Approach 1:
The coil formers are pre-positioned obliquely on the base body before final alignment. This preliminary oblique positioning allows the assembly process to proceed while subsequently enabling the alignment operation to generate the necessary axial bracing forces that secure the stator laminates during final assembly
Solution Approach 2:
The coil formers are designed to be movable from an oblique initial position to a final aligned position. During alignment, the coil formers are subjected to forces that cause them to pivot and settle into their final positions, dynamically generating axial bracing forces that secure the stator laminates
2Ease of manufacture
If stator laminates are assembled with standard tolerances, then manufacturing is feasible, but air gaps occur between laminates negatively impacting magnetic flux guidance
Solution Approach 1:
The alignment process applies preliminary forces to the coil formers and stator laminates before final assembly is complete. These forces pre-compress the laminates and eliminate air gaps that would otherwise form due to tolerance accumulation, ensuring tight laminate contact throughout the assembled structure
Solution Approach 2:
The oblique to aligned positioning mechanism creates a progressive compression effect on the stator laminates during assembly. The geometric arrangement of the coil formers and their movement path generate distributed compressive forces that uniformly press the laminates together, eliminating gaps caused by tolerances
3Reliability
If high clamping force is required for axial bracing, then stator laminate security improves, but alignment force requirements increase
Solution Approach 1:
The coil formers are initially positioned obliquely rather than directly axially. This oblique arrangement creates a geometric lever arm that allows alignment forces applied in one direction to generate larger axial bracing forces through mechanical advantage, effectively transforming the alignment operation into a force-multiplying mechanism
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 approach enhances assembly security, reduces air gaps, and ensures reproducible motor behavior by providing axial bracing and tolerance compensation, resulting in improved magnetic flux guidance and stator stability.
Implementation Method 1
the alignment involves axial bracing of the stator laminates... With appropriate lever ratios, axial bracing of the stator laminates can be achieved, with a very considerable clamping force, while only a small alignment force need be applied
Implementation Method 2
the coil formers are designed to be flexible, in particular on the frame inner face which is axially opposite the pivoting stud and, in particular, to have crushing ribs
Data Source
AI summary
The invention relates to a stator for an electric motor having a base body composed of stator laminates which are axially in layers with respect to a motor axis and having a number of frame-like coil formers which are fitted with stator windings, with the coil cross-sectional surfaces of said frame-like coil formers essentially being directed at the motor axis. It is proposed that in order to fit them, the coil formers can first of all be placed obliquely with respect to a final position on coil former holders of the base body and can then be aligned in the final position, and in that the arrangement is designed such that the alignment involves axial bracing of the stator laminates.