Stator Core Segments With Variable Staking For Induction Heating
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Solution Overview
Problem
Existing stator core designs face challenges in uniformly setting thermosetting resin within stator coils due to difficulties in impregnating and retaining the resin, leading to inconsistent fixation of the stator coil to the stator core.
Innovation Solution
The stator core is composed of laminated steel sheets with varying numbers of staking portions, where first steel sheets with more staking portions are arranged at the ends and second steel sheets with fewer staking portions are at the center, allowing for a controlled temperature rise gradient during induction-heating to effectively set the thermosetting resin at desired positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator core is induction-heated to set the thermosetting resin, then the stator coil can be fixed to the stator core, but the temperature rise gradient in the stator core segments becomes uncontrolled, making it difficult to retain and set the thermosetting resin at desired positions
Solution Approach 1:
The patent applies local quality by creating different thermal characteristics in different regions of the stator core. Steel sheets with different numbers of staking portions are arranged in the axial direction, causing localized variations in heat generation and retention. This enables controlled temperature distribution across the stator core, allowing the thermosetting resin to be properly set at desired positions while maintaining reliable fixation.
2Ease of manufacture
If the thermosetting resin is applied in liquid state to the stator coil, then it can be impregnated into the coil, but it is difficult to retain the liquid resin at the predetermined portions
Solution Approach 1:
The patent applies preliminary action by arranging steel sheets with different numbers of staking portions before the resin setting process. This pre-configured structure creates predetermined thermal zones that will hold and set the thermosetting resin at specific positions. The differentiated staking portions prepare the thermal field in advance, enabling the liquid resin to be retained and properly set at desired locations.
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 configuration ensures reliable and uniform setting of the thermosetting resin across the stator core segments, enhancing the fixation of the stator coil and improving the thermal management of the stator core.
Implementation Method 1
the stator coil is fixed to the stator core by a thermosetting resin that is set by induction-heating the stator core
Implementation Method 2
each of the stator core segments is formed by laminating a plurality of steel sheets in the axial direction of the stator core
Data Source
AI summary
A stator for an electric rotating machine includes an annular stator core, an outer cylinder fitted on a radially outer surface of the stator core, and a stator coil mounted on the stator core. The stator core is comprised of a plurality of stator core segments that are arranged in a circumferential direction of the stator core so as to adjoin one another in the circumferential direction. The stator coil is fixed to the stator core by a thermosetting resin that is set by induction-heating the stator core. Each of the stator core segments is formed by laminating a plurality of steel sheets in an axial direction of the stator core and fixing at least some of the steel sheets by staking. The number of staking portions formed in one of the steel sheets is different from the number of staking portions formed in another one of the steel sheets.