Stator Laminations with Perforation Patterns for Vibration Attenuation
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Solution Overview
Problem
Existing electric machine designs face challenges in attenuating low-frequency noise and vibration emissions, which can lead to acoustic and vibratory disturbances, particularly due to structure-borne transmission through the stator, and current solutions are often ineffective in the low-frequency range.
Innovation Solution
The introduction of a stator design featuring a plurality of stacked laminations with patterned perforations, where each lamination has a unique pattern of perforations that disrupts vibration paths while maintaining unbroken electromagnetic flux, allowing for tunable sound absorption properties and reduced vibration transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional stator design is used, then manufacturing is simple, but vibration and noise attenuation is insufficient
Solution Approach 1:
The stator is divided into multiple laminations with different perforation patterns, where each lamination is segmented to disrupt vibration paths while maintaining electromagnetic functionality. The perforations segment the solid stator structure into a patterned configuration that attenuates vibration transmission.
Solution Approach 2:
Different regions of the stator laminations are given different local qualities through varied perforation patterns. Each lamination has specific perforation arrangements tailored to its position and function, creating local variations in mechanical properties while maintaining overall electromagnetic performance.
2Object-affected harmful factors
If perforations are added to laminations, then vibration transmission is reduced, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into standardized steps: creating uniform perforation patterns on individual laminations using consistent methods, then stacking them in a specific sequence. This segmentation allows each lamination to be manufactured independently with the same tooling, reducing overall manufacturing complexity despite the added perforation feature.
3Object-affected harmful factors
If multiple laminations with different patterns are stacked, then vibration attenuation is enhanced, but device complexity increases
Solution Approach 1:
The vibration attenuation function is segmented across multiple laminations rather than concentrated in a single complex structure. Each lamination contributes to the overall attenuation effect through its specific perforation pattern, and the segmented stacking arrangement creates cumulative vibration disruption without requiring any single component to be overly complex.
Solution Approach 2:
Adjacent laminations are designed with asymmetric or different perforation patterns relative to each other, creating an asymmetric stack configuration. This asymmetry in the stacking sequence ensures that vibration paths are disrupted at multiple levels, enhancing attenuation while maintaining a systematic manufacturing approach.
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 configuration effectively attenuates structure-borne vibrations and noise emissions, improving the operational quality of electric machines by reducing unwanted acoustic and vibratory disturbances with minimal impact on torque capability and manufacturing costs.
Implementation Method 1
At least one of the stacked laminations of the stator includes a pattern of perforations disposed at a yoke portion of the stator to attenuate structure-bore transmission of vibration during operation of the electric machine
Implementation Method 2
In an electric motor, the stator generates a rotating magnetic field that drives the rotating armature
Implementation Method 3
While operating as a generator, the stator converts the rotating magnetic field of the rotor into electric current
Data Source
AI summary
An electric machine includes a stator formed from a plurality of stacked laminations and defining a center bore and a rotor disposed within the center bore. The rotor is configured to output a rotational torque in response to an input current delivered to the stator. At least one of the stacked laminations of the stator includes a pattern of perforations disposed at a yoke portion of the stator to attenuate structure-bore transmission of vibration during operation of the electric machine.