Stator Core Recess Bonding for Accurate Rotating Machine Assembly
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Solution Overview
Problem
Conventional stator cores of rotating electric machines face issues with reduced assembly accuracy and productivity due to adhesives used for fixing electromagnetic steel sheets, leading to increased eddy currents and hysteresis losses, and instability in assembly accuracy when attachment frames are fitted.
Innovation Solution
A stator core design where adhesion portions are formed continuously or intermittently on recesses of core pieces in the axial direction, allowing for precise alignment and fixation without adhering to insulators, and a manufacturing method involving stamping, alignment, adhesive application, curing, and division of core pieces to maintain assembly accuracy and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to outer peripheral surface of stacked core for fixing electromagnetic steel sheets, then fixation strength is improved, but assembly accuracy is reduced due to adhesive interference with attachment frame fitting
Solution Approach 1:
The adhesive is applied locally only to the end surfaces of core pieces at recess positions, rather than to the entire outer peripheral surface. This localized application ensures fixation strength at specific points while preventing adhesive from interfering with the attachment frame fitting on the outer peripheral surface, thus resolving the contradiction between fixation strength and assembly accuracy
Solution Approach 2:
The adhesive application is segmented to specific locations (end surfaces of core pieces at recesses) rather than continuous application. This segmentation allows the adhesive to provide necessary fixation at critical points while leaving other areas free for precise assembly operations, thereby maintaining both fixation strength and assembly accuracy
2Reliability
If adhesive is permeated into all areas between several hundreds of electromagnetic steel sheets to fix the stacked core, then fixation reliability is improved, but productivity is reduced due to the complex and time-consuming process
Solution Approach 1:
Instead of permeating adhesive into all areas between several hundreds of electromagnetic steel sheets, the adhesive is applied only to specific end surfaces of core pieces at recess positions. This segmented approach maintains fixation reliability at critical locations while dramatically reducing the time and complexity of the adhesive application process, thereby improving productivity
Solution Approach 2:
The adhesive application process extracts only the essential fixation points (end surfaces at recesses) from the entire stack, rather than treating every interface between steel sheets. This extraction of critical fixation points maintains sufficient fixation reliability while eliminating unnecessary adhesive application steps, thus resolving the productivity issue
3Strength
If adhesive is applied to contact surfaces of stacked cores for assembly, then bonding strength is improved, but assembly accuracy becomes unstable
Solution Approach 1:
The adhesive is applied locally to specific end surfaces of core pieces at recess positions rather than to the entire contact surfaces. This localized application provides sufficient bonding strength at critical joints while preventing adhesive from spreading to areas that require precise alignment, thus maintaining stable assembly accuracy
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 reduces eddy current losses, enhances assembly accuracy, and increases productivity by minimizing adhesive application points, thereby improving the efficiency and performance of rotating electric machines.
Implementation Method 1
an adhesion portion is formed on the core pieces continuously or intermittently in the axial direction at a recess formed to extend in the axial direction on the core pieces
Data Source
AI summary
A stacked core is formed by stacking, in an axial direction, a plurality of core pieces each having a core-back portion and a tooth portion. An adhesion portion is formed on the core pieces continuously or intermittently in the axial direction at a recess formed to extend in the axial direction on the core pieces on at least one of an end surface of an outer periphery of the tooth portion and an end surface of an outer periphery of the core-back portion of the stacked core.