Stator Core Water Resistance via Reversed Lamination and Sealing
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Solution Overview
Problem
The existing stator cores in electric motors face issues with water resistance due to large gaps formed by burrs on the thin plates, which can allow cutting fluids to enter when the motor is used in applications like machine tools without a housing covering the outer circumferential surface.
Innovation Solution
A stator core design where large-diameter thin plates are laminated in a reversed arrangement with small-diameter thin plates sandwiched between them, minimizing the gap between burrs and enhancing water resistance by using a sealing agent and adjusting the plate thicknesses to control burr heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thin plates are laminated in a reversed arrangement to reduce cogging, then motor characteristics are improved, but large gaps between burrs are created reducing water resistance
Solution Approach 1:
A sealing agent is applied as an intermediary substance between the laminated thin plates to fill the gaps created by burrs. The sealing agent penetrates into the gaps and forms a waterproof barrier, preventing cutting fluid from entering the motor while maintaining the reversed lamination arrangement for reduced cogging.
Solution Approach 2:
The plate thickness is specifically controlled to be 0.15mm or less, which changes the physical parameters of the thin plates. This parameter change allows the burrs to be positioned in a way that creates smaller gaps compared to thicker plates, thereby improving water resistance while maintaining the cogging reduction benefits.
2Reliability
If plate thickness is reduced to minimize gap between burrs, then water resistance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a precise parameter range for plate thickness (0.15mm or less) that optimizes the balance between water resistance and manufacturability. This parameter change creates conditions where the burr gaps are naturally minimized, improving water resistance without requiring excessively tight manufacturing tolerances.
Solution Approach 2:
Multiple thin plates with consistent thickness parameters are mass-produced using standardized punching processes. By creating copies of precisely dimensioned plates with controlled burr characteristics, the manufacturing precision requirement is managed through replication of proven designs rather than custom fabrication of each plate.
3Adaptability or versatility
If housing covering the stator core is omitted for machine tool applications, then adaptability is improved, but water resistance deteriorates
Solution Approach 1:
The sealing agent serves as a protective intermediary layer between the external environment and the stator core laminations. This allows the motor to operate without a housing in machine tool applications while the sealing agent prevents cutting fluid from penetrating into the motor interior through the burr gaps.
Solution Approach 2:
The burrs that initially create harmful gaps are converted into a beneficial structure by applying the sealing agent. The sealing agent fills these gaps and transforms them into sealed pathways, converting the potential harm of exposed burr gaps into a benefit where the sealed structure provides enhanced protection against fluid ingress.
Data Source
AI summary
A stator core of an electric motor is provided with a first core block and a second core block formed by laminating a plurality of large-diameter thin plates in a reversed arrangement with respect to each other causing outer circumferential edge burrs of the large-diameter thin plates to face each other, and with a small-diameter thin plate sandwiched between the first core block and the second core block, and having an outer diameter smaller than the cuter diameter of the large-diameter thin plate.