Stator Divided Core Convex Connecting Surface Stress Reduction
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Solution Overview
Problem
Existing stators with divided cores face challenges in efficiently attaching coils and reducing stress concentration during operation, which affects manufacturing efficiency and core strength.
Innovation Solution
A stator design featuring an annular back yoke and teeth with divided cores, where the radial width of the back yoke is smaller than the circumferential width of the teeth, and a convex or concave connecting surface allows for easy coil attachment and stress reduction by enabling smooth fitting and welding of the coils to the teeth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a coil unit is produced in advance and fitted to a tooth, then manufacturing efficiency is improved, but stress concentration in the core during operation increases
Solution Approach 1:
The core is divided into multiple divided cores (first divided core, second divided core, etc.) that can be assembled separately. Each divided core includes a tooth and a divided back yoke portion. This segmentation allows coil units to be pre-produced and fitted to individual teeth, improving manufacturing efficiency while the modular structure reduces stress concentration during operation.
Solution Approach 2:
The connecting surfaces between divided back yoke portions are designed with specific local geometries (convex and concave portions) that optimize both coil attachment and stress distribution. The radial width of divided back yoke portions is controlled to be smaller than or equal to the circumferential width of teeth, creating localized structural features that reduce stress concentration while maintaining manufacturing efficiency.
2Ease of manufacture
If the radial width of the divided back yoke is made smaller than or equal to the circumferential width of the tooth, then coil attachment is facilitated, but the structural integrity of the core may be compromised
Solution Approach 1:
The connecting surfaces between divided back yoke portions feature convex and concave curved portions that enable smooth fitting and welding of coils to teeth. The curved geometry facilitates coil attachment by providing a tapered entry path while maintaining structural integrity through continuous stress distribution across the curved surfaces.
Solution Approach 2:
The core structure combines divided back yoke portions with teeth to form a composite assembly. The divided back yoke portions are positioned and connected to create a unified structure that maintains structural integrity while enabling easy coil attachment through the controlled radial width and connecting surface geometry.
3Strength
If divided cores are used with connecting surfaces, then stress concentration is reduced, but device complexity increases
Solution Approach 1:
The core is segmented into multiple divided cores with standardized connecting surface features. Each divided core includes convex and concave portions that interlock, reducing stress concentration through distributed load paths. The modular segmentation allows for simplified assembly while maintaining structural strength.
Solution Approach 2:
Multiple divided cores are merged through their connecting surfaces to form a unified core structure. The convex portions of one divided core fit into the concave portions of adjacent divided cores, creating a integrated assembly that reduces stress concentration while avoiding the complexity of a monolithic core design.
Data Source
AI summary
Provided is a stator that can easily attach a coil to a tooth and that can reduce concentration of stress generated in the core during the operation. The stator includes a core with an annular back yoke, and a plurality of teeth; and a coil wound around each of the plurality of teeth. The core includes a plurality of divided cores each of which having a divided back yoke. A connecting surface is arranged at an end on a second circumferential side of the divided yoke, the connecting surface being a plane or a convex surface extending from a side surface on the second circumferential side of the tooth to an outer circumferential surface of the divided back yoke.