Segmented Stator Core Locking via Radial Spoke Grooves
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Solution Overview
Problem
Segmented stator core sections in axial flux electric motors are prone to fall out due to high magnetic forces, leading to failure.
Innovation Solution
Incorporation of radial spokes within radial grooves on the pole shoes of segmented core sections, which provide a locking mechanism to prevent stator core sections from moving towards the rotor, using non-magnetic insulate frames and soft magnetic composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segmented stator core sections are used in axial flux electric motors, then the motor can be manufactured with improved ease of assembly and manufacturing flexibility, but the stator core sections are prone to fall out due to high magnetic forces
Solution Approach 1:
The stator core is divided into multiple segmented core sections that can be manufactured and assembled separately. Each segment is supported by the insulate frame structure, allowing for easier manufacturing and assembly while maintaining the segmented configuration for magnetic performance.
Solution Approach 2:
The radial spokes are positioned within radial grooves formed in the pole shoes of the segmented core sections. This nested configuration where the spoke fits into the groove creates a locking mechanism that prevents the core sections from falling out while maintaining a compact structure.
Solution Approach 3:
The insulate frame acts as an intermediary structure between the segmented core sections and the rotor. It provides mechanical support and positioning for the core sections, preventing them from being pulled toward the rotor by magnetic forces while maintaining the necessary magnetic circuit integrity.
2Reliability
If radial spokes are positioned within radial grooves to lock core sections, then stator core section retention is improved, but device complexity increases
Solution Approach 1:
The radial spokes are positioned within radial grooves formed in the pole shoes of the segmented core sections. This nested configuration where the spoke fits into the groove creates a locking mechanism that prevents the core sections from falling out while maintaining a compact structure.
Solution Approach 2:
The locking mechanism is integrated into the existing structure by forming radial grooves directly in the pole shoes of the core sections. The radial spokes, which are part of the insulate frame structure, serve dual purposes: providing mechanical support and acting as locking elements, thereby reducing the need for separate locking components.
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
Prevents stator core section fall out and reduces cogging in the electric motor by securely fastening the core sections and optimizing their alignment with the central axis.
Implementation Method 1
a radial spoke is positioned between each adjacent pair of segmented core sections, and at least one radial spoke extends across each axial end of each one of the plurality of segmented core sections
Data Source
AI summary
A stator core assembly for an axial flux electric motor for an automobile includes a cylindrical outer case that defines a central axis, first and second disk shaped insulate frames axially spaced from one another and positioned within the outer case, each of the first and second insulate frames including a circular outer ring, a circular inner ring and a plurality of radial spokes extending between the outer ring and the inner ring and spaced circumferentially about the central axis, and a plurality of segmented core sections extending axially between the first and second insulate frames spaced circumferentially around and supported by the first and second insulate frames, wherein, a radial spoke is positioned between each adjacent pair of segmented core sections, and at least one radial spoke extends across each axial end of each one of the plurality of segmented core sections.