Stator Lamination Stacking for Winding Access and Slot Fill
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Solution Overview
Problem
Conventional monolithic stator cores face difficulties in winding stator windings due to narrow gaps between teeth, leading to low slot fill factor and material utilization, and complex assembly processes in segmented stator structures.
Innovation Solution
The method involves assembling a laminated stator by fixing and coaxially spacing lamination stacks with staggered teeth, allowing for easier winding with a single continuous wire and reducing the need for numerous wire connections, and intermeshing the stacks to form a stator with improved alignment and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional monolithic stator core is used, then the structure is simple, but the gap between teeth must be wide enough to pass the winding needle which reduces slot fill factor and material utilization
Solution Approach 1:
The stator core is divided into multiple laminations stacked together to form the complete stator. Each lamination contains teeth with wider gaps suitable for winding needle passage, while the stacked laminations collectively achieve high slot fill factor and material utilization comparable to conventional monolithic structures.
Solution Approach 2:
The invention transitions from a single-plane (2D) monolithic stator core to a multi-layer (3D) stacked lamination structure. By adding the axial dimension with multiple laminations, the design achieves both wide gaps for easy winding in each lamination and high overall slot fill factor through the cumulative effect of stacked laminations.
2Quantity of substance
If segmented stator structures are used to achieve high slot fill factor, then material utilization improves, but the assembly process becomes complicated with multiple segments and numerous wire connections
Solution Approach 1:
The stator is segmented into multiple laminations that are stacked together, achieving high slot fill factor. However, unlike conventional segmented stators requiring complex assembly of multiple separate stator segments, these laminations are designed to be stacked in sequence with standardized interfaces, simplifying the assembly process.
Solution Approach 2:
Multiple laminations are combined by stacking them coaxially in sequence, merging their individual structures into a unified stator core. This combining approach achieves the benefits of segmented structures (high slot fill factor) while maintaining assembly simplicity through standardized stacking procedures.
3Ease of operation
If teeth are wound individually while separate from the stator, then winding ease improves, but the assembly process becomes complicated with interlocking structures and numerous wire connections
Solution Approach 1:
The winding operation is performed preliminarily on each lamination while it is still separate and accessible, making the winding process easier. The laminations are then stacked and secured together, completing the assembly without requiring complex interlocking structures or numerous wire connections.
Solution Approach 2:
The stator is divided into separable laminations that can be individually wound before assembly. This segmentation allows easy winding access for each lamination while the final stacked structure maintains structural integrity without requiring complex connection mechanisms.
Data Source
AI summary
A laminated stator and a method for making a laminated stator of an electric motor. The method includes arranging a plurality of stator laminations into lamination stacks spaced axially from one another, each lamination stack including a first group of stator laminations including an annular portion and a plurality of tooth portions extending from a periphery of the annular portion, and a second group of stator laminations including only tooth portions positioned to correspond with the tooth portions of said first group. The method further includes winding stator windings around selected subsets of the plurality of teeth while the lamination stacks are spaced axially and meshing the lamination stacks with one another so the annular portions of the lamination stacks are axially adjacent one another and the plurality of teeth are intermeshed with the plurality of another stack.