Stator Core-Back Welding Layout for Low-Loss Deformation Control
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Solution Overview
Problem
Conventional electric rotating machines face issues with deformation due to fastening stress, increased noise and vibration from welding, and high production costs due to additional components and complex manufacturing processes.
Innovation Solution
The electric rotating machine incorporates a stator iron core with welding portions that extend along the stacking direction between end portions, providing additional rigidity and suppressing deformation, while minimizing material usage and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If welding is applied to all parts of electromagnetic steel plates in the stacking direction to form a reinforced portion, then the stator iron core deformation is suppressed, but iron loss increases due to short-circuiting among steel plates
Solution Approach 1:
The patent applies welding only to specific local regions (core-back portions at both end portions in the stacking direction) rather than all parts of the electromagnetic steel plates. This localized welding approach provides sufficient reinforcement to suppress deformation while minimizing the welding area to reduce short-circuiting and iron loss.
2Stability of the object's composition
If welding is applied to all parts of electromagnetic steel plates in the stacking direction to form a reinforced portion, then the stator iron core deformation is suppressed, but noise and vibration increase due to separation at tooth portions
Solution Approach 1:
The patent strategically locates welding portions at the core-back portions at both end portions of the stacking direction, away from the tooth portions. This local welding placement reinforces the structure to prevent deformation while avoiding the tooth regions where welding-induced separation would cause noise and vibration.
Solution Approach 2:
The patent extracts the welding function from the tooth portions and relocates it to the core-back portions at the end portions. This separation of welding locations eliminates the harmful effects (noise and vibration) that would occur if welding were applied at the tooth portions, while still achieving the desired deformation suppression.
3Stability of the object's composition
If fastening stress suppression plates are provided at both stacking-direction end portions, then deformation is suppressed, but material cost and production cost increase
Solution Approach 1:
The patent merges the fastening stress suppression function with the existing core-back portions of the electromagnetic steel plates. By forming welding portions directly at these core-back portions, the patent eliminates the need for separate fastening stress suppression plates, thereby reducing material cost while achieving the same deformation suppression effect.
Solution Approach 2:
The core-back portions are given multiple functions: they serve as both structural components of the stator iron core and as locations for welding to provide fastening stress suppression. This multi-functionality eliminates the need for additional dedicated suppression plates, reducing material cost.
4Stability of the object's composition
If the number of welding portions is increased, then deformation suppression is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies welding partially rather than comprehensively across all electromagnetic steel plates. By providing welding portions only at the core-back portions at both end portions of the stacking direction, the patent achieves sufficient deformation suppression with a limited number of welding locations, thereby simplifying the manufacturing process and reducing complexity.
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 results in a high-efficiency, low-cost electric rotating machine with reduced noise, vibration, and iron loss, maintaining performance even with thinner electromagnetic steel plates.
Implementation Method 1
core-back portion has a welding portion that extends from a stacking-direction end portion along the stacking direction so as to ride on the two or more electromagnetic steel plates
Implementation Method 2
stator iron core is fixed to the housing through shrink-fitting or press-fitting
Implementation Method 3
stator iron core is fixed to the housing through shrink-fitting or press-fitting
Data Source
AI summary
An outer-circumferential side of a core-back portion of a stator iron core has a welding portion that is provided in such a way as to ride on two or more electromagnetic steel plates including electromagnetic steel plates situated at a stacking-direction end portion of the stator iron core; the welding portion is provided partly in the stacking-direction of the stator iron core.