Stator Pole Manufacturing via Laminar Protrusion Bending
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Solution Overview
Problem
Existing processes for manufacturing electric motors are inefficient due to the need for costly shearing operations and complex assembly methods, particularly with grain-oriented ferromagnetic materials, which require crystal orientation and result in waste and increased manufacturing complexity.
Innovation Solution
A process involving a laminar body made from ferromagnetic material with elongated bases and protrusions, where coils are inserted and the terminal zones are deformed using cutting and bending to form stator poles, eliminating the need for shearing and simplifying the manufacturing process without requiring crystal orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If shearing operations are used to manufacture pole ends, then the pole ends can be produced as separate components, but this generates waste scraps and requires costly industrial slicers
Solution Approach 1:
The invention merges the pole end production with the stator body by forming protrusions directly on the stator body from the same ferromagnetic material, eliminating the need for separate pole end components and the waste associated with shearing operations
Solution Approach 2:
The protrusions are formed preliminarily on the stator body before coil insertion, allowing coils to be directly inserted into the protrusions without subsequent assembly operations
2Reliability
If grain-oriented ferromagnetic materials are used, then magnetic flux support is improved, but crystal orientation is required which complicates manufacturing
Solution Approach 1:
The invention uses traditional ferromagnetic materials instead of expensive grain-oriented materials, accepting slightly lower magnetic performance in exchange for dramatically simplified manufacturing without crystal orientation requirements
3Ease of manufacture
If pole ends are applied separately after stator assembly, then coil insertion is facilitated, but connection means are required which decrease reliability
Solution Approach 1:
The protrusions are formed preliminarily on the stator body before coil insertion, allowing coils to be directly inserted into the protrusions without subsequent assembly operations or connection means
Solution Approach 2:
The pole ends (protrusions) are merged with the stator body as integral components, eliminating the need for separate connection means such as mortise and tenon joints
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 approach reduces waste, lowers manufacturing costs, and simplifies the production of electric motors by avoiding expensive slicing machines and complex assembly, while improving magnetic flux efficiency through the use of traditional iron materials.
Implementation Method 1
The poles are surrounded by coils of electrically conductive material, which are supplied with electric current which magnetises the poles and forces an electromagnetic interaction with the rotor
Implementation Method 2
deforming the terminal zones of the laminar protrusions so that the terminal zones have a bent form
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
A process for manufacturing an outer stator (11; 111; 211; 311; 411; 511) for an electric motor (13; 113; 213; 313; 413; 513) is described, said stator (11; 111; 211; 311; 411; 511) comprising stator poles (2; 102; 202; 302; 402; 502) surrounded by coils (5; 105; 205; 305; 405; 505), said process including the following steps: - preparing a laminar body (1; 101; 201; 301; 401; 501), of ferromagnetic material, with elongated form and provided with laminar protrusions (2; 102; 202; 302; 402; 502); - inserting a coil (5; 105; 205; 305; 405; 505) of conductive material around each of said laminar protrusions (2; 102; 202; 302; 402; 502); - deforming the terminal zones (7; 107; 207; 307; 407; 507) of said laminar protrusions (2; 102; 202; 302; 402; 502) such that said terminal zones (7; 107; 207; 307; 407; 507) assume a preferably outwardly curved form; - closing said laminar body (1; 101; 201; 301; 401; 501) such that said laminar protrusions (2; 102; 202; 302; 402; 502) are in internal position and adapted to serve as stator poles.