Stator Core Divided Cores Wedge Bonding Assembly
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Solution Overview
Problem
Existing stator core manufacturing techniques face challenges in achieving high strength while maintaining easy manufacturability and improved assembly workability without increasing magnetic resistance loss.
Innovation Solution
The stator core design features a configuration with inner and outer circumferential protrusions and notches, along with central recesses and protrusions, allowing for specific contact points and gap dimensions that enhance bonding strength and manufacturability, including a wedge shape for the contact parts and a larger outer circumferential protrusion width to improve structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If divided cores are assembled with conventional bonding surfaces, then assembly workability is improved, but bonding strength is insufficient
Solution Approach 1:
The bonding surface is designed with non-uniform thickness, creating a wedge shape where the thickness varies from the end facing another divided core to the opposite end. This local variation in geometry concentrates the bonding action at specific regions, improving both assembly ease and bonding strength simultaneously.
Solution Approach 2:
The bonding surface employs an asymmetric wedge shape rather than a symmetric configuration. The thickness varies asymmetrically across the bonding surface, with one end being thinner and the other thicker, creating directional bonding characteristics that enhance assembly workability while maintaining high bonding strength.
2Strength
If divided cores are assembled with tight bonding, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The bonding surface is segmented into distinct regions with different thickness characteristics. The wedge shape creates natural segmentation where the thinner end and thicker end serve different functional purposes, simplifying the manufacturing process while achieving high bonding strength through the segmented geometry.
3Ease of manufacture
If divided cores are assembled with uniform bonding surfaces, then manufacturing is simplified, but assembly accuracy decreases
Solution Approach 1:
The wedge-shaped bonding surface is pre-formed during the manufacturing process, creating a built-in alignment feature. The varying thickness provides preliminary positioning guidance that improves assembly accuracy without requiring additional manufacturing steps or complex assembly procedures.
Data Source
AI summary
A stator core is configured by assembling divided cores in an annular shape. Each core includes a yoke part extending in a circumferential direction, and having opposite first and second facing sections. The first facing section includes an inner circumferential protrusion, an outer circumferential protrusion, and a central recess. The second facing section includes an inner circumferential notch, an outer circumferential notch, and a central protrusion. When the cores are assembled, the inner circumferential protrusion faces the inner circumferential notch, the outer circumferential protrusion faces the outer circumferential notch, and the central recess faces the central protrusion, and the outer circumferential protrusion is formed so as to have a width larger in a direction orthogonal to a circumference direction than that of the inner circumferential protrusion.