Induction Motor Stator Core with Extended Teeth
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Solution Overview
Problem
Stator core designs for induction motors face challenges in optimizing performance while reducing costs and minimizing noise, with existing designs struggling to facilitate simple and cost-effective manufacturing and assembly.
Innovation Solution
The design features a stator core with a toroidal structure, including a circumferential yoke and radially extending teeth, where the teeth are at least three times the yoke thickness, allowing for optimal motor performance and cost-effectiveness by using a high ratio of tooth length to yoke thickness, which mitigates noise and enables the use of cost-effective wiring materials like aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stator core designs with shorter teeth are used, then manufacturing and assembly are simpler, but motor performance is suboptimal and noise is higher
Solution Approach 1:
The patent applies parameter changes by specifying that the tooth length shall be at least three times the yoke thickness, representing a significant deviation from conventional dimensional ratios. This parameter change optimizes the magnetic circuit and motor performance while the patent acknowledges the resulting increase in manufacturing complexity through specialized punching tools and processes
2Object-affected harmful factors
If longer teeth with higher tooth length to yoke thickness ratio are used, then motor performance is optimized and noise is reduced, but manufacturing becomes more complex and costly
Solution Approach 1:
The patent uses parameter changes by establishing the specific ratio requirement of tooth length being at least three times the yoke thickness. This dimensional parameter optimization reduces noise through improved magnetic flux distribution and reduced saturation, while the patent acknowledges the need for specialized manufacturing approaches
Solution Approach 2:
The patent applies segmentation by dividing the stator core into multiple laminations that are punched and stacked. This allows the complex long-tooth geometry to be manufactured through repetitive punching of individual laminations rather than as a single piece, facilitating the unconventional dimensions while managing manufacturing complexity
3Volume of moving object
If unconventional tooth and yoke dimensions are used, then slot volume is maximized for wiring and flux saturation is controlled, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by specifying the tooth length to yoke thickness ratio of at least 3:1, which directly maximizes the slot volume available for wiring. This dimensional change increases the slots' capacity to accommodate conductors while the patent acknowledges the corresponding increase in manufacturing precision requirements for maintaining acceptable flux saturation
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 optimizes motor performance at low horsepowers, reduces noise, and allows for cost-effective manufacturing by using unconventional tooth and yoke dimensions, maximizing slot volume for wiring and maintaining acceptable flux saturation.
Implementation Method 1
The inner yoke margin is spaced radially from the inner core margin by a tooth length. The tooth length is at least three (3) times the yoke thickness.
Implementation Method 2
The stator includes a generally toroidal core. The core includes a generally circumferential yoke and a plurality of arcuately spaced apart teeth extending radially inwardly from the yoke.
Data Source
AI summary
An induction motor assembly includes a motor. The motor includes a rotor rotatable about a rotor axis, and a stator at least substantially circumscribing the rotor. The stator includes a generally toroidal core. The core includes a generally circumferential yoke and a plurality of arcuately spaced apart teeth extending radially inwardly from the yoke. The tooth length is at least three (3) times the yoke thickness.