Stator Core Segmentation for Uniform Slot Width
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Solution Overview
Problem
Conventional rotary electric machines with annular stators suffer from uneven space factors in slots, leading to magnetic imbalances and potential damage to insulating films due to mismatched slot widths.
Innovation Solution
The stator core is configured with a uniform slot width by linking separated cores in a circumferential direction, where the first and second slots have equal widths, and the second slot uses a thicker insulating component to accommodate coil conductors, ensuring balanced magnetic distribution and reduced insulating film damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the slot width is made larger than the coil conductor width to enable smooth insertion, then the ease of operation is improved, but the space factor of the coil conductor is reduced
Solution Approach 1:
The stator core is divided into multiple separated cores that are linked together in the circumferential direction. This segmentation allows the slots to be formed by the combined structure of multiple cores, enabling uniform slot widths that optimize both coil conductor insertion and space factor without requiring excessive slot width for insertion ease.
2Quantity of substance
If the difference between slot width and coil conductor width is reduced to increase space factor, then the quantity of substance is improved, but the insulating film of the coil conductor is damaged by the edge of the teeth portions
Solution Approach 1:
By segmenting the stator core into multiple separated cores, the patent achieves uniform slot widths that are optimized for both coil conductor insertion and space factor. The uniform width, combined with the specific structure of separated cores, prevents concentration of stress on insulating films while maximizing the space factor.
3Manufacturing precision
If separated cores are linked to form the stator core, then the manufacturing precision is improved through uniform slot width, but the device complexity increases
Solution Approach 1:
The stator core is constructed from multiple separated cores that are linked together. Each separated core can be manufactured independently with standardized dimensions, ensuring uniform slot widths when assembled. This segmentation approach improves manufacturing precision while the modular nature of separated cores actually simplifies the overall manufacturing process compared to creating a single complex annular core.
Solution Approach 2:
Multiple separated cores are linked together in the circumferential direction to form the complete annular stator core. This merging of multiple simpler components creates the final structure with uniform slot widths, achieving manufacturing precision through assembly of standardized parts rather than manufacturing a single complex piece.
Data Source
AI summary
A side surface at the outside of a plurality of teeth portions of one separated core is faced to a side surface of teeth portions of an adjacent separated core, so as to form a second slot which is straddled between the adjacent separated cores, and a first slot is formed by a plurality of teeth portions of one separated core, and a width size of the first slot is identical to a width size of the second slot, and coil conductor storage space is formed in the first slot via a first insulating component, and coil conductor storage space is formed in the second slot via a second insulating component, and a thickness size of the first insulating component is different from a thickness size of the second insulating component.