Stator Split Cores Alternating Rolling Direction Strain Reduction
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Solution Overview
Problem
The existing stator designs with split cores punched out from electrical steel sheets, when arranged in an arc shape, can lead to strain and increased cogging torque, resulting in motor performance deviations from the initially expected rotation characteristics.
Innovation Solution
The stator design incorporates split cores with alternating rolling directions and push-back processing to ensure accurate alignment and connection, reducing strain and cogging torque by maintaining the intended curvature and improving yield during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If split cores are punched out and arranged in an arc shape with connected core backs, then the stator can be manufactured, but strain occurs and cogging torque increases
Solution Approach 1:
The stator core is divided into multiple split cores that are punched out separately from the electrical steel sheet. Each split core is then individually arranged and connected to form the complete annular stator core, allowing for precise control of each segment's position and orientation
Solution Approach 2:
Adjacent split cores are arranged with alternating rolling directions (first rolling direction for one core, second rolling direction for the next core). This asymmetric alternating pattern prevents cumulative strain and reduces cogging torque while maintaining the annular shape
2Shape
If split cores are bent around connected portions to form an arc shape, then the annular stator core can be formed, but strain occurs in the core
Solution Approach 1:
The split cores are punched out with pre-determined orientations and rolling directions before assembly. The alternating rolling directions are established in advance during the punching process, so that when the cores are assembled into the annular shape, the strain is distributed evenly and minimized rather than concentrated through bending
Data Source
AI summary
A stator is formed by laminating electrical steel sheets punched into a predetermined shape. The stator includes split cores that are punched out from the electrical steel sheets to have an annular shape. A first group of the split cores adjacent to each other in the circumferential direction have the same rolling direction, and a second group of the split cores adjacent to each other in the circumferential direction have different rolling directions.