Stator Core Structure for Crimping Strength Without Distortion
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Solution Overview
Problem
Conventional motor stator cores experience distortion and dimensional inaccuracies due to plastic deformation during crimping or welding, affecting motor characteristics and accuracy.
Innovation Solution
A stator core design featuring a plastically deformable annular core back with varying distances from the central axis, which includes a deformable portion that acts as a detent to enhance fixing strength and prevent eccentricity, allowing for uniform stress distribution and reduced distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crimping is performed at the core back part to join stacked steel sheets, then the joining strength is improved, but the core back part undergoes plastic deformation causing distortion of the entire stator core
Solution Approach 1:
The core back is divided into a non-deformable part (maintaining dimensional accuracy) and a deformable part (absorbing deformation). This segmentation allows crimping to be performed without distorting the entire stator core, as the deformation is localized to the deformable part only.
Solution Approach 2:
The deformable part is extracted as a separate functional element from the core back. This extracted deformable part specifically absorbs the plastic deformation during crimping, protecting the main core back and tooth parts from distortion while still enabling strong joining.
2Strength
If crimping is performed at the tooth part to join stacked steel sheets, then the joining strength is improved, but the tooth part deforms affecting motor characteristics
Solution Approach 1:
The deformable part is extracted from the tooth part and relocated to the core back. This extraction ensures that crimping forces are applied only to the deformable part, completely preventing tooth part deformation and preserving motor characteristics while still achieving strong joining.
Solution Approach 2:
The deformable part acts as an intermediary element that absorbs the crimping forces. Instead of applying crimping forces directly to the tooth part, the deformable part serves as a mediator that takes the deformation, protecting the tooth part from any adverse effects.
3Manufacturing precision
If the core back is made rigid to maintain dimensional accuracy, then the manufacturing precision is improved, but the ability to suppress eccentricity through detent action is reduced
Solution Approach 1:
The core back is segmented into a rigid non-deformable part (providing dimensional accuracy) and a flexible deformable part (providing detent action). This segmentation allows the core back to simultaneously maintain dimensional accuracy while suppressing eccentricity through the detent action of the deformable part.
Solution Approach 2:
Different parts of the core back have different mechanical properties: the non-deformable part has high rigidity for dimensional accuracy, while the deformable part has lower rigidity to enable detent action. This local quality differentiation allows both functions to coexist without compromising either dimensional accuracy or eccentricity suppression.
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 design effectively suppresses distortion and displacement, resulting in improved motor characteristics and dimensional accuracy while maintaining the structural integrity of the stator core.
Implementation Method 1
a plastically deformable portion 111 that has an annular shape around the central axis J1 and that is below the core back 11 in an axial direction
Data Source
AI summary
A stator core includes a core back having an annular shape around a central axis, teeth extending outward from the core back in a radial direction, and an inner peripheral surface located inside the core back in the radial direction and extending from an upper end to a lower end of the core back around the central axis. The core back includes a plastically deformable portion having an annular shape around the central axis and disposed below the core back in the axial direction. At least a portion of the plastically deformable portion has a different distance from the central axis than another portion of the core back.