Stator Core Snap-Fit Coupling for Rotating Electrical Machines
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Solution Overview
Problem
Existing stator designs for rotating electrical machines require complex manufacturing processes and increased numbers of parts due to the need for multiple types of laminated steel sheets and caulking, as well as mechanisms to prevent positional shifts during assembly.
Innovation Solution
A stator design featuring core pieces with a magnetic material and insulators, where a snap-fit coupling mechanism allows rotation while restricting axial displacement, reducing the number of parts and manufacturing steps by using a pillar portion and open ring structure for secure connection without additional jigs or equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laminated steel sheets are engaged at connecting portions to connect core pieces, then connection strength is improved, but the number of member types increases and the manufacturing process becomes complicated
Solution Approach 1:
The connecting portion integrates multiple functions into a single structure: the first core piece has a protrusion that serves as both a positioning element and a connecting element, while the second core piece has a corresponding recess that receives the protrusion. This merging eliminates the need for separate connecting members or multiple types of laminated steel sheets, reducing device complexity while maintaining connection strength
Solution Approach 2:
The protrusion and recess structure serves multiple functions simultaneously: it provides mechanical connection between core pieces, ensures proper positioning during assembly, and maintains structural integrity. This multi-functional design replaces what would otherwise require multiple specialized components, thereby reducing the number of member types
2Ease of operation
If a mechanism for extracting or inserting core pieces is provided, then connection and rotation are enabled, but a holding mechanism is required to prevent positional shift, complicating the manufacturing process
Solution Approach 1:
The coupling mechanism allows dynamic movement during assembly: the protrusion can be inserted into the recess to enable connection, and the structure permits rotation about the connection axis. After assembly, the same structure provides static positioning by preventing axial displacement. This dynamic-to-static transition eliminates the need for separate holding mechanisms
Solution Approach 2:
The protrusion-recess structure is self-sufficient: it enables both the connection function and the positioning function without requiring additional holding mechanisms. The geometry of the protrusion and recess inherently prevents axial displacement while allowing the required connection and rotation operations, making the system self-serviceing
3Area of stationary object
If core pieces are positioned close together on the inner side in the radial direction, then space utilization is improved, but winding becomes difficult due to interference with adjacent core pieces
Solution Approach 1:
The solution moves the connection mechanism from the radial dimension to the axial dimension. The protrusion and recess are positioned on the outer peripheral surfaces of the core pieces, allowing connection in the axial direction while maintaining close radial positioning. This dimensional separation enables both compact radial arrangement and easy winding operations
Data Source
AI summary
A stator has a plurality of core pieces being arranged in a ring shape around a rotation axis, and is configured such that a coupling part having a fitting structure is formed between the core pieces adjacent to each other in an arrangement of the ring shape, the coupling part allowing rotation about a pillar portion and restricting displacement in the axis direction by a snap-fit coupling that is formed with the pillar portion being provided on the yoke side of one of the core pieces and extending in a direction parallel to the axis and an open ring portion being provided on the yoke side of the other of the core pieces.