Stator Core Split Core Interlocking and Heat Shrink Roundness
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Solution Overview
Problem
The manufacturing process of stator cores formed from split cores arranged in a circumferential direction often results in uneven clamping forces during heat shrinking, leading to positional issues and adverse effects on the roundness of the stator core's inner peripheral side, increasing manufacturing complexity and cost.
Innovation Solution
The stator core design incorporates split cores with protruding and depressed portions that fit together, restricting movement and maintaining position, while the cylindrical body features a buffer portion to absorb rigidity differences, ensuring even clamping forces and improved roundness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cylindrical body is heat shrunk to secure the split cores, then the split cores are clamped and secured, but the uneven temperature distribution causes uneven clamping force that makes split cores come out of position
Solution Approach 1:
The invention divides the cylindrical body into multiple independent temperature control zones, allowing each zone to be heated to different temperatures. This segmentation enables even clamping force distribution across all split cores during heat shrinking, preventing positional deviations and maintaining roundness of the stator core inner peripheral side.
Solution Approach 2:
The invention applies different heating conditions to different local regions of the cylindrical body. By controlling temperature distribution locally in each heating zone, the system achieves uniform clamping force on the split cores despite the cylindrical body's large size, thereby resolving the contradiction between securing reliability and manufacturing precision.
2Manufacturing precision
If the temperature of the entire cylindrical body is adjusted to make clamping force even, then clamping force uniformity is improved, but device size and complexity increase
Solution Approach 1:
Instead of controlling the entire cylindrical body as a single zone, the invention segments it into multiple independent heating zones. Each zone can be controlled separately with simpler individual controllers, achieving overall uniform clamping force without requiring a single complex global control system.
Solution Approach 2:
The invention transitions from uniform temperature control in one dimension to multi-dimensional temperature distribution control. By adding spatial dimensionality to temperature control (different zones at different temperatures), the system achieves even clamping force while keeping each local control unit relatively simple.
3Manufacturing precision
If the temperature of the entire cylindrical body is adjusted to make clamping force even, then clamping force uniformity is improved, but manufacturing time increases
Solution Approach 1:
By dividing the cylindrical body into multiple heating zones that can be controlled independently, the system can optimize heating time for each zone based on its specific requirements. This parallel processing approach reduces total manufacturing time compared to heating the entire body uniformly, while still achieving even clamping force distribution.
Solution Approach 2:
The invention changes the temperature parameter distribution across different zones of the cylindrical body. By adjusting temperature parameters locally in each zone rather than uniformly across the entire body, the system achieves even clamping force more efficiently, reducing the overall heating time required while maintaining manufacturing precision.
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 design enhances the roundness of the stator core by preventing split cores from shifting during the manufacturing process, reducing manufacturing time and complexity, and ensuring consistent clamping forces, thereby improving the efficiency and cost-effectiveness of the stator core formation.
Implementation Method 1
The first end portion has a protruding portion that protrudes outward in the circumferential direction, and the second end portion has a depressed portion that is depressed inward in the circumferential direction and fits together with the protruding portion of the first end portion of an adjacent split core
Implementation Method 2
In the process of inserting the split cores into the cylindrical body and shrink fitting the cylindrical body, the split cores are clamped and secured by heat shrinking the cylindrical body
Data Source
AI summary
A stator includes a stator core formed from a plurality of split cores arranged in a circumferential direction, and a cylindrical body that surrounds the stator core from a periphery and secures the stator core. The split cores each have a first end portion on one end in the circumferential direction, and a second end portion on the other end in the circumferential direction. The first end portion has a protruding portion that protrudes outward in the circumferential direction, and the second end portion has a depressed portion that is depressed inward in the circumferential direction and fits together with the protruding portion of the first end portion of an adjacent split core.