Stator Block Crimping Offset for Cogging Torque Reduction
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Solution Overview
Problem
The existing technology for stators formed by laminated steel plates, where crimping processing leads to partial deformation, resulting in uneven magnetic field flow and increased cogging torque.
Innovation Solution
The stator is designed by overlaying blocks with crimping positions offset relative to each other, ensuring that at least one crimping position of one block does not overlap with the crimping position of another block, either by varying the number or position of crimping positions, thereby canceling out cogging torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crimping processing is performed on laminated steel plates to join them, then the steel plates are integrated, but partial deformation occurs leading to uneven magnetic field flow and increased cogging torque
Solution Approach 1:
The patent applies asymmetry by intentionally offsetting the crimping positions of adjacent blocks in the axial direction. Instead of aligning crimping positions symmetrically, each block's crimping positions are shifted relative to its neighbors, creating an asymmetric pattern that balances the magnetic field distortion and reduces cogging torque while maintaining joining strength
Solution Approach 2:
The patent applies local quality by varying the crimping position offset for different blocks along the axial direction. Each block has its crimping positions strategically positioned relative to adjacent blocks, creating locally optimized magnetic field distribution that collectively reduces overall cogging torque
2Ease of manufacture
If crimping positions are aligned between adjacent blocks, then manufacturing is simplified, but magnetic field flow becomes uneven and cogging torque increases
Solution Approach 1:
The patent deliberately introduces asymmetry in crimping position arrangement between adjacent blocks. By offsetting the crimping positions rather than aligning them, the patent creates an asymmetric pattern that balances magnetic field distortion effects and reduces cogging torque, while the offset amount can be controlled to maintain manufacturing feasibility
Data Source
AI summary
A stator includes blocks formed by integrating laminated steel plates by crimping. The stator is formed by overlaying a plurality of the blocks in an axial direction of the stator, and is formed such that in a plane that a pair of the blocks face each other, at least one crimping position of one of the blocks and a crimping position of the other of the blocks do not overlap with each other, when the stator is viewed from the axial direction.