Electric Motor Stator Segmented Radial Assembly
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Solution Overview
Problem
Existing electric motor production methods result in high mass and cost due to complex assembly processes, which are not environmentally friendly.
Innovation Solution
The electric motor is composed of stamped-packaged toothed segments with a tongue and groove system for radial connection and axially pushed-on end caps with wire guidance, eliminating the need for a surrounding ring and allowing for simplified, automated, and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a surrounding ring is used to hold toothed segments radially, then the stator structure is stable, but the mass increases and production becomes more complex
Solution Approach 1:
The invention removes the surrounding ring component from the stator assembly. Instead of using a ring to hold the toothed segments radially, the segments are directly connected to each other through radial pushing, eliminating unnecessary mass while maintaining structural stability.
Solution Approach 2:
The stator is divided into multiple stamped-packaged toothed segments that can be independently produced and then radially pushed together. This segmentation allows for simplified production of individual components and easier assembly without requiring a surrounding ring to hold them.
2Stability of the object's composition
If traditional assembly methods are used with surrounding rings, then structural stability is achieved, but production time increases and automation becomes difficult
Solution Approach 1:
The stator is segmented into multiple toothed segments that can be independently manufactured and then quickly assembled by radial pushing. This modular approach enables automated assembly processes and significantly reduces production time compared to traditional methods requiring surrounding rings.
Solution Approach 2:
The toothed segments are pre-formed with stamped packaging that facilitates their radial pushing together during assembly. This preliminary preparation of components with appropriate geometries enables rapid automated assembly without requiring complex surrounding ring structures.
3Reliability
If complex assembly processes are used, then structural integrity is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The stator is divided into standardized toothed segments with consistent geometries for radial pushing. This segmentation simplifies the manufacturing process by allowing identical components to be produced using the same stamping and winding processes, reducing overall manufacturing complexity while maintaining integrity.
Solution Approach 2:
The invention removes the surrounding ring component and associated complex assembly steps. The toothed segments are directly connected through radial pushing with axial holding, eliminating unnecessary components and simplifying the manufacturing process while maintaining structural integrity.
4Loss of energy
If end caps with wire guidance grooves are added to each toothed segment, then copper filling increases and engine utilization improves, but device complexity increases
Solution Approach 1:
The end caps with wire guidance grooves are integrated directly onto each toothed segment, merging multiple functions into a single component. This integration allows for optimized wire routing and higher copper filling within the stator segments without requiring separate external components, thus improving engine utilization without significantly increasing overall device complexity.
Data Source
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AI summary
Electric motor, comprising a stator, which at least comprises stamped and stacked tooth segments, wherein the tooth segments are capable of being pushed radially together during production and of being held together by holding parts which have been pushed on axially.