Stator Insulator Geometry for Magnetic Saturation Control
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Solution Overview
Problem
Existing electric motors face a reduction in torque due to magnetic flux density saturation in the stator, which affects their performance.
Innovation Solution
The stator design includes an insulator with specific angled faces and a yoke configuration that increases the cross-sectional area for magnetic flux passage, reducing the likelihood of magnetic saturation and enhancing coil alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the stator core uses a conventional design with limited cross-sectional area for magnetic flux passage, then the structure is simpler and easier to manufacture, but magnetic saturation occurs reducing torque performance
Solution Approach 1:
The insulator's second face transitions from a conventional flat perpendicular face to an inclined face configuration, changing the geometric dimension and orientation of the magnetic flux passage path. This dimensional change increases the effective cross-sectional area available for magnetic flux without increasing the overall stator size, thereby preventing magnetic saturation and maintaining torque performance while managing structural complexity
Solution Approach 2:
The patent changes the geometric parameters of the insulator, specifically the angle and inclination of the second face relative to the yoke. By adjusting these parameters, the cross-sectional area for magnetic flux passage is optimized to prevent saturation. This parameter optimization allows the stator to maintain high torque performance while the insulator structure remains manufacturable through controlled geometric variations
2Ease of manufacture
If the insulator second face is perpendicular to tooth protrusion direction, then the manufacturing is simpler, but magnetic flux density saturation occurs in the yoke
Solution Approach 1:
The insulator's second face is designed with asymmetric inclination rather than a symmetric perpendicular configuration. This asymmetric geometry creates an optimized magnetic flux distribution pattern that prevents concentration and saturation in the yoke, improving magnetic flux density stability while remaining manufacturable through standard machining or molding processes that can accommodate inclined surfaces
3Reliability
If the cross-sectional area for magnetic flux passage is increased, then magnetic saturation is prevented, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Rather than uniformly increasing the cross-sectional area throughout the entire stator, the patent applies the inclined face configuration locally at the insulator's second face where it interfaces with the yoke. This localized geometric modification concentrates the magnetic flux in an optimized path, preventing saturation at critical points without requiring a complete redesign of the entire stator structure, thus maintaining manufacturing feasibility
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 effectively prevents magnetic saturation, maintaining torque and improving coil alignment, thereby enhancing the performance of the rotary electric machine.
Implementation Method 1
there has been a demand to substantially prevent a reduction of the torque of the electric motor due to the saturation of magnetic flux density (magnetic saturation) in the stator
Data Source
AI summary
A stator includes a stator core, an insulator, and a coil. The stator core includes: a yoke having an annular shape; and teeth protruding from the yoke to the inside of the yoke. The insulator covers at least a part of the stator core. The insulator includes: a first face facing the coil wound around the teeth; and a second face facing the yoke. The first face is perpendicular to the protrusion direction of the teeth. The second face includes: a first perpendicular face perpendicular to the protrusion direction of the teeth; and a first inclined face inclined toward the first face with respect to the first perpendicular face. The yoke includes an inner circumferential face facing the second face.