Stator Core Piece Structure for Lower Magnetoresistance
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Solution Overview
Problem
Existing axial gap type rotary electric machines have suboptimal magnetic characteristics due to inefficiencies in the design and production of stator cores, leading to increased magnetoresistance and reduced magnetic flux transmission.
Innovation Solution
A core piece design featuring a green compact with soft magnetic particles arranged in a specific aspect ratio and orientation, integrated into a stator core with a columnar and plate-like structure, optimized for reduced grain boundaries and enhanced magnetic flux passage, produced using a novel molding process that aligns with the radial direction of the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stator core design is used, then manufacturing is simpler, but magnetic characteristics are suboptimal with increased magnetoresistance
Solution Approach 1:
The stator core is divided into multiple core pieces, each comprising a first member (column form) and a second member (plate form) integrally molded together. This segmentation allows for optimized magnetic flux passage in each component while maintaining overall core functionality, resolving the contradiction between improved magnetic characteristics and structural complexity.
Solution Approach 2:
The soft magnetic particles are configured with specific aspect ratios in different regions: the first member has particles with aspect ratio ≥1.2 in radial and axial directions, while the second member has particles with aspect ratio ≥1.2 in radial and circumferential directions. This local optimization of particle orientation improves magnetic characteristics in specific regions without requiring complete redesign of the entire core structure.
2Reliability
If soft magnetic particles are arranged with high aspect ratio, then magnetic flux transmission is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The invention specifies precise parameter ranges for soft magnetic particle aspect ratios (≥1.2) in different members and orientations. By establishing clear quantitative parameters for particle configuration, the invention enables controlled optimization of magnetic flux transmission while providing measurable targets for manufacturing quality control, thus managing the precision requirements systematically.
3Productivity
If green compact is used for core piece production, then manufacturing efficiency is improved, but particle orientation control becomes more difficult
Solution Approach 1:
The soft magnetic particles are pre-configured with appropriate aspect ratios and orientation characteristics before being compacted into the green compact form. This preliminary preparation of particle properties ensures that when the compacting process is applied for efficient manufacturing, the particles are already positioned and oriented to achieve the desired magnetic characteristics, thus resolving the contradiction between production efficiency and orientation control.
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 solution results in a stator core that significantly improves magnetic characteristics by minimizing grain boundaries, reducing magnetoresistance, and enhancing the transmission of magnetic flux, leading to a more efficient axial gap type rotary electric machine with improved performance.
Implementation Method 1
enhancing the transmission of magnetic flux
Implementation Method 2
soft magnetic particles having a flat shape
Data Source
AI summary
A core piece includes a first member in a column form and a second member in a plate form, the first member and the second member being configured by a green compact in which the first member and the second member are integrally formed, the green compact includes a plurality of soft magnetic particles having a flat shape, a first average aspect ratio of the soft magnetic particles is greater than or equal to 1.2 in a first cross section of the first member, a second average aspect ratio of the soft magnetic particles is greater than or equal to 1.2 in a second cross section of the second member, each of the first average aspect ratio and the second average aspect ratio is related to an average of lengths of soft magnetic particles in a direction of the stator core.