Electric Motor Stator Segmented Core Crimping Alignment
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Solution Overview
Problem
Conventional electric motors installed in limited spaces, such as engine rooms, face challenges in achieving high output and efficiency due to space constraints, which limit the design freedom and result in reduced driving force.
Innovation Solution
A stator design for electric motors featuring a yoke with a non-circular closed loop shape and multiple slots of varying lengths, allowing for equal turns of coils wound around different phases, enabling flexible design and maximizing space utilization without altering the existing installation position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional stator with a crimping portion is used, then the stator can be assembled with the rotor, but manufacturing precision deteriorates due to misalignment between the crimping portion and slot opening
Solution Approach 1:
The stator core is segmented into multiple laminations that are stacked together. The crimping portion is formed by bending the edge of these laminations, creating a segmented structure that allows precise alignment with slot openings while maintaining ease of assembly. This segmentation enables the crimping portion to be accurately positioned relative to the slot openings without requiring complex one-piece construction.
Solution Approach 2:
The crimping portion is pre-formed by bending the lamination edges before final assembly with the rotor. This preliminary formation of the crimping structure ensures that the alignment with slot openings is established in advance, improving manufacturing precision while facilitating subsequent assembly operations.
2Strength
If the crimping portion is positioned deeper to increase contact area with the rotor, then connection strength improves, but the stator core length increases
Solution Approach 1:
The crimping portion is designed with localized bending at specific positions along the lamination edge, creating concentrated contact areas with the rotor. This local quality approach provides sufficient connection strength at critical points without requiring the entire stator core to be longer, thus maintaining compact overall dimensions while achieving strong mechanical connection.
3Strength
If the number of strokes in the stamping die is increased to form the crimping portion, then connection strength improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The formation of the crimping portion is merged with the existing stamping die structure used for manufacturing the stator core. By integrating the crimping formation into the standard stamping process rather than requiring separate additional strokes or specialized equipment, the connection strength is achieved without significantly increasing device complexity or manufacturing difficulty.
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 design enhances motor output and efficiency while providing design flexibility by allowing the same number of turns on each phase, even in constrained spaces, thus preventing the reduction in driving force and heat loss.
Implementation Method 1
a stator core for an electric motor, the stator core comprising: a stator yoke (131); a plurality of stator teeth (132) extending radially inwardly from both end surfaces of the stator yoke (131)
Data Source
Figure 1~2
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AI summary
A stator for an electric motor is provided. A stator for an electric motor according to an example embodiment of the present invention comprises: at least one coil; and a stator core including a yoke formed in a closed loop shape and a slot part extended from the yoke by a predetermined length. The slot part includes a plurality of slots forming a multi-phase including a first phase and a second phase different from the first phase. The total number of turns obtained by summing up the turns of the coils respectively wound on the plurality of slots forming the first phase may be the same as the total number of turns obtained by summing up the turns of the coils respectively wound on the plurality of slots forming the second phase.