Rotating Machine Stator Housing Segmented Holding Surfaces
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Solution Overview
Problem
Rotating electrical machines with helically wound cylindrical stacked cores face issues due to gaps between layers, leading to corrosion, magnetic noise, and stress on fastening components, which existing countermeasures fail to fully address without increasing size or production cost.
Innovation Solution
A stator mounting mechanism that modifies the housing structure to hold the core stack with different thicknesses in inner and outer peripheral regions, using a spigot and socket joint mechanism to alleviate gap issues without altering the core stack, ensuring firm holding and reducing stress on fastening components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the core sheet is helically rolled up to form a cylindrical stacked core, then material waste is reduced and yield rate is increased, but gaps form between adjacent wound layers causing corrosion and magnetic noise
Solution Approach 1:
The holding surface is segmented into multiple annular surfaces (first annular surface, second annular surface, third annular surface) that contact different regions of the core stack. This segmentation allows independent control of holding pressure at different locations, enabling the gaps between wound layers to be eliminated while maintaining the helical winding structure's productivity benefits.
Solution Approach 2:
Different regions of the core stack are provided with different local qualities through the multi-level annular surfaces. The first annular surface contacts the inner peripheral region, the second annular surface contacts the outer peripheral region, and the third annular surface contacts the intermediate region. This local differentiation allows targeted elimination of gaps in different areas while maintaining overall structural integrity.
2Manufacturing precision
If pressing is applied to the core stack to decrease gaps, then gap size is reduced, but the end surface is lifted up or excessive stress is applied to fastening bolts
Solution Approach 1:
The holding surface is divided into multiple annular surfaces that distribute the pressing force across different regions of the core stack. This segmentation prevents concentration of stress at single points, thereby reducing the lifting effect on the end surface and minimizing excessive stress on fastening bolts while still achieving gap elimination.
Solution Approach 2:
Different annular surfaces apply different local pressing forces to different regions of the core stack. The multi-level structure allows the inner peripheral region, outer peripheral region, and intermediate region to be pressed with appropriate local forces, preventing uniform over-compression that would cause end surface lifting or bolt stress.
3Object-affected harmful factors
If additional thick annular plates are disposed on ends of the stacked core to eliminate gaps, then gap elimination is achieved, but device size and production cost increase
Solution Approach 1:
The housing structure is given multi-functionality by incorporating the holding surface with multiple annular surfaces that simultaneously serve as both the mounting structure and the gap-elimination mechanism. This eliminates the need for separate additional thick annular plates, maintaining device simplicity while achieving gap elimination.
Solution Approach 2:
The gap elimination function is extracted from a separate component (additional annular plates) and integrated into the existing housing structure through the multi-level annular holding surfaces. This extraction eliminates the need for extra components, reducing device complexity and production cost while maintaining effective gap elimination.
Data Source
AI summary
A rotating electrical machine having holding surfaces on a pair of housings which firmly holds a stator core made of a core stack. The holding surfaces have a small-diameter first annular surface and a large-diameter second annular surface arranged at different locations in the axial direction. The surfaces in contact with inner and outer circumferential regions of a yoke hold the core. Two contacts between the housing and core are in different locations on a radial and axial direction. An outer peripheral side of the yoke where plate thickness is smaller and an inner peripheral side where plate thickness is larger are pressed individually in the axial direction. A firm holding feature suitable for configuration of the yoke is ensured to setting a difference in level between the contacts Eliminating problems about gaps created between layers of the core stack without any changes to the structure of the core stack.