Stator Core Manufacturing With Pre-Treated Teeth Connectors
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Solution Overview
Problem
The existing manufacturing methods for stator cores in rotary electric machines result in magnetic flux leakage at teeth-connecting parts, leading to deteriorated output characteristics and increased processing time due to non-magnetization treatments applied after lamination, which can alter the dimensions of core sheets.
Innovation Solution
A method where a second annular part with integrally formed teeth and teeth-connecting parts is punched out from a sheet material pre-treated with non-magnetization, allowing for reduced processing time and stabilized quality by integrating the parts without additional post-lamination treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-magnetization treatment is applied to all teeth-connecting parts after the annular teeth member is formed, then magnetic flux leakage is reduced, but processing time increases significantly
Solution Approach 1:
The non-magnetization treatment is performed on the sheet material before punching out the annular teeth member. This preliminary action ensures that when the teeth-connecting parts are formed, they already have reduced magnetic permeability, preventing magnetic flux leakage without requiring additional treatment steps after assembly.
Solution Approach 2:
The non-magnetization treatment is applied selectively to specific regions of the sheet material corresponding to where teeth-connecting parts will be formed, rather than treating the entire annular teeth member uniformly. This localized treatment reduces processing time while still preventing magnetic flux leakage at the critical teeth-connecting parts.
2Reliability
If non-magnetization treatment is applied to core sheet materials before lamination, then magnetic flux leakage is reduced, but the total treatment time increases due to the number of sheets
Solution Approach 1:
Multiple core sheet materials are stacked and treated together as a single unit in the non-magnetization treatment step. This combining approach allows simultaneous treatment of all sheets, reducing the total treatment time compared to treating each sheet individually before lamination.
3Reliability
If additional non-magnetization treatment is performed on punched core sheets or laminates, then magnetic flux leakage is reduced, but dimensional accuracy changes
Solution Approach 1:
The non-magnetization treatment is performed on the sheet material before punching, when the material is still in its original state. This prevents dimensional changes that would occur if treatment were applied after punching or lamination, as the subsequent punching process maintains the dimensional accuracy of the already-treated material.
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 processing time while maintaining the dimensional accuracy and quality of the stator core, preventing magnetic flux leakage and improving the motor's output characteristics.
Implementation Method 1
a step for subjecting the sheet material, prior to punching out the second annular part, to a non-magnetization treatment in a section of the sheet material corresponding to the teeth-connecting part
Data Source
AI summary
Disclosed is a method for manufacturing a stator core including multiple teeth around which a coil is to be wound, a teeth-connecting part that connects adjacent ones of the teeth, and a first annular part having, on an inner circumferential part thereof, multiple fitting parts to be respectively fitted with the teeth. The manufacturing method includes: (a) a step for punching out, from a sheet material, an inner core (second annular part) in which the teeth and the teeth-connecting part are formed integrally; (b) a step for subjecting the sheet material, prior to the punching of the inner core, to a non-magnetization treatment in a section of the sheet material corresponding to the teeth-connecting part; and (c) a step for fitting the first annular part and the inner core by the fitting parts.