Stator Core Manufacturing Using Segmented T-Shaped Teeth
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Solution Overview
Problem
Conventional stator core manufacturing processes result in significant material waste and inefficiencies due to the use of expensive and stress-sensitive soft magnetic alloys, particularly in the stamping process, which leads to high costs and reduced efficiency in electric motor operations.
Innovation Solution
A method involving the cutting of a jigsaw pattern into T-shaped teeth, which are then stacked and wound without slot gaps, placed along a ferromagnetic tube, and vacuum encapsulated in epoxy resin, reducing material waste and improving winding fill ratio and Eddy current efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional stamping process is used to manufacture stator cores, then manufacturing simplicity is maintained, but material waste increases and manufacturing cost increases
Solution Approach 1:
The stator core is divided into multiple individual teeth that are manufactured separately and then stacked together. Each tooth is cut from laminated sheets using a precision cutting process that minimizes waste. The segmented teeth are then assembled into stacks with precise alignment, reducing overall material waste while maintaining manufacturing feasibility through modular assembly.
Solution Approach 2:
The invention transitions from a planar stamping approach to a three-dimensional stacking approach. Teeth are cut from laminated sheets with optimized nesting patterns, then stacked vertically to form the stator core. This dimensional transition allows for more efficient material utilization in the cutting process and reduces waste while maintaining ease of manufacture through standardized stacking procedures.
2Reliability
If soft magnetic alloys are used for stator manufacturing, then magnetic flux density and hysteresis characteristics are improved, but manufacturing cost increases
Solution Approach 1:
The stator core is segmented into multiple teeth made from soft magnetic alloy laminated sheets. By cutting and stacking these teeth individually, the invention minimizes material waste, thereby reducing the overall quantity of expensive soft magnetic alloy required. This segmentation strategy maintains the superior magnetic properties where needed while controlling total material cost.
Solution Approach 2:
The invention changes the geometric parameters of the teeth through precision cutting and stacking, optimizing the arrangement and orientation of soft magnetic alloy layers. This parameter optimization ensures that the expensive soft magnetic material is used most efficiently, achieving desired magnetic flux density and hysteresis characteristics with minimal material quantity.
3Ease of manufacture
If stamped teeth are used in stator construction, then manufacturing process is simple, but stress and material waste are introduced
Solution Approach 1:
Instead of stamping teeth from solid blocks or large sheets, the invention segments the stator core into individual teeth made from thin laminated sheets. These laminated teeth are then stacked together, eliminating the high-stress stamping process while maintaining manufacturing simplicity through standardized lamination and stacking procedures.
Solution Approach 2:
The invention replaces the mechanical stamping process with a cutting and stacking process. Thin laminated sheets are cut into tooth shapes using precision cutting methods that apply minimal stress, then stacked to form the complete stator core. This substitution eliminates the high-stress deformation associated with conventional stamping while maintaining ease of manufacture.
4Productivity
If conventional stamping and stacking is used, then manufacturing is straightforward, but winding fill ratio and Eddy current efficiency are reduced
Solution Approach 1:
The stator core is segmented into precisely cut and stacked teeth that create optimized slots for winding placement. This segmentation allows for better winding arrangement and higher fill ratios compared to conventional stamped cores. The straightforward manufacturing process is maintained through standardized lamination, cutting, and stacking procedures.
Solution Approach 2:
The invention uses vacuum consolidation during the stacking process to ensure tight, uniform alignment of laminated teeth without excessive stress. This vacuum application improves the precision of tooth positioning and slot geometry, thereby enhancing winding fill ratio and reducing Eddy currents, while maintaining manufacturing straightforwardness through an automated vacuum consolidation step.
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 method effectively reduces material waste, allows for the use of more expensive soft magnetic alloys, enhances winding uniformity, and improves the efficiency and power density of electric motors by minimizing Eddy currents and rotor losses.
Implementation Method 1
vacuum encapsulating the inner space in an epoxy resin
Implementation Method 2
placing the stacks along a perimeter of a polygonal inner surface of a ferromagnetic tube
Data Source
AI summary
A method of manufacturing a stator core including stacking a plurality of teeth into a plurality of stacks, said teeth are obtained from a jigsaw pattern of said teeth, said teeth are substantially identical to each other in size, each said tooth is substantially T-shaped via two arms protruding sideways from a leg, said teeth substantially aligning with each other in each said stack; winding said stacks with a plurality of windings; placing said stacks along a perimeter of a polygonal inner surface of a ferromagnetic tube, said inner surface defining an inner space within said tube, each side of said polygonal inner surface corresponding to each said stack and contacting the bases of said legs of each said stack; inserting a shaft into said inner space, the top surfaces of said arms facing said shaft; vacuum encapsulating said inner space in an epoxy resin; removing said shaft.