Radial Flux Motor Stator Encapsulation for Axial Fixation and Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing radial flux motors face challenges in reliably securing the stator, particularly in high-voltage applications where heat generation and magnetic forces can cause misalignment and instability.
Innovation Solution
A stator arrangement for a radial flux motor that includes a stator housing, a stator, and an encapsulation body. The stator is embedded radially, axially, and/or circumferentially within the encapsulation body, which is form-fittingly connected to the stator housing, providing secure fixation of the stator in the axial direction through undercuts and a thermal connection for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator is secured using conventional fastening methods, then the stator can be fixed in position, but the stator may become misaligned or unstable under magnetic forces and heat-induced expansion in high-voltage applications
Solution Approach 1:
The patent merges the stator fixation function with the stator housing structure by using an encapsulation body that integrally surrounds and secures the stator. This combined structure eliminates the need for separate fastening components and provides stable positioning under magnetic forces and thermal expansion, resolving the contradiction between fixation reliability and alignment stability.
Solution Approach 2:
The encapsulation body changes the physical state of the stator from a loose component to an embedded structure within the housing. By transforming the stator's positional state through encapsulation, the system achieves both reliable fixation and alignment stability under operating conditions, including high-voltage magnetic forces and heat-induced expansion.
2Reliability
If multiple separate fastening components are used to secure the stator, then the stator can be firmly fixed, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple fastening functions into a single encapsulation body structure that surrounds the stator. This integration eliminates the need for multiple separate fastening components, reducing device complexity and assembly steps while maintaining reliable stator fixation under magnetic forces and thermal conditions.
Solution Approach 2:
The encapsulation body serves multiple functions simultaneously: it acts as a structural housing component, a fastening mechanism, a thermal management interface, and a positioning element. This multi-functionality reduces the overall number of components needed while achieving reliable stator fixation with simplified device complexity.
3Loss of energy
If the stator is tightly secured to reduce power losses, then efficiency improves, but heat dissipation becomes more difficult
Solution Approach 1:
The encapsulation body provides different local qualities: tight encapsulation in radial and circumferential directions to reduce power losses from misalignment, while maintaining controlled thermal pathways for heat dissipation. This localized differentiation of fixation tightness versus thermal management resolves the contradiction between energy loss reduction and temperature control.
Solution Approach 2:
The encapsulation body acts as an intermediary between the stator and the external environment, providing mechanical coupling to reduce power losses while simultaneously serving as a thermal interface for heat dissipation. This intermediary structure mediates between the conflicting requirements of tight securing and effective cooling.
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
The solution provides a reliable and cost-effective method for securing the stator, reducing power losses, and enhancing thermal management, thus addressing the challenges of heat generation and magnetic forces in high-voltage radial flux motors.
Implementation Method 1
The encapsulation body (50) is form-fittingly connected to the stator housing (20) in such a manner that the stator (40) is fixed at least in the axial direction (2) in the stator housing (20) by the encapsulation body (50)
Implementation Method 2
providing secure fixation of the stator in the axial direction through undercuts and a thermal connection for improved heat dissipation
Data Source
AI summary
A stator arrangement (10) for a radial flux motor (100) having an axis of rotation (100a). The stator arrangement (10) comprises a stator housing (20), a stator (40) and an encapsulation body (50). The stator housing (20) defines a circumferential portion (30) for receiving the stator. The stator (40) is arranged on the circumferential portion (30). Furthermore, the stator (40) is encapsulated in the stator housing (20), wherein the encapsulation body (50) is form-fittingly connected to the stator housing (20) in such a manner that the stator (40) is secured at least in the axial direction (2) in the stator housing (20) by the encapsulation body (50).