Segmented Motor Stator Teeth With Deformable Axle Press-Fit
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Solution Overview
Problem
Existing stators for electric motors face challenges in assembly due to forces that can cause individual teeth to separate during assembly or when joined to the axle, leading to disassembly or damage. Additionally, the need for high accuracy in manufacturing both the teeth and the axle complicates the assembly process.
Innovation Solution
A stator design featuring a laminated stator core with individual teeth that are interconnected in the circumferential direction, each with a connection portion for mechanical fixation and a radially inner pressing portion for establishing a press-fit connection with the axle. The pressing portions can be elastically or plastically deformed to secure the stator to the axle, limiting forces that could separate the teeth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If individual teeth are interconnected in the circumferential direction with connection portions, then the stator structure is stabilized and teeth are prevented from separating, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The stator is divided into multiple individual teeth that are interconnected in the circumferential direction through connection portions. This segmentation allows for modular assembly while maintaining structural stability, as each tooth can be independently positioned and then connected to its neighbors to form the complete stator structure.
Solution Approach 2:
The connection portions are pre-formed on the individual teeth during manufacturing, preparing them for subsequent assembly. This preliminary preparation of connection features eliminates the need for complex joining operations during assembly, thereby reducing assembly time while ensuring structural stability.
2Manufacturing precision
If form-fitting connection is used between individual teeth and axle, then manufacturing accuracy is improved, but the assembly difficulty increases due to tight tolerances
Solution Approach 1:
The pressing portions are designed to undergo elastic and/or plastic deformation during assembly, changing their dimensional parameters to accommodate the axle. This deformation capability allows the connection to tolerate manufacturing variations while still achieving a secure fit, reducing the stringency of tolerance requirements.
Solution Approach 2:
The connection portions are designed with inherent compliance through elastic and plastic deformation capabilities, which act as a cushion against manufacturing tolerances. This beforehand cushioning allows for easier assembly by accommodating dimensional variations without requiring extremely tight tolerances.
3Ease of operation
If pressing portions are designed for elastic and plastic deformation, then assembly ease is improved and tolerance compensation is enabled, but the structural strength may be reduced
Solution Approach 1:
The pressing portions are designed to undergo controlled elastic and plastic deformation during assembly, temporarily changing their dimensional parameters to accommodate the axle. After assembly, the material's memory and structural design allow the pressing portions to maintain sufficient strength while having provided the necessary compliance during the joining process.
Solution Approach 2:
The pressing portions transition from a rigid state during normal operation to a deformable state during assembly. This dynamic behavior allows the material to be compliant when needed (during assembly) while maintaining structural integrity during service, effectively managing the strength-compliance trade-off.
4Reliability
If high manufacturing accuracy is required for both teeth and axle, then connection reliability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The pressing portions are designed to undergo elastic and plastic deformation during assembly, changing their dimensional parameters to accommodate the axle. This deformation capability allows the connection to tolerate manufacturing variations while still achieving a secure fit, reducing the stringency of tolerance requirements and simplifying manufacturing processes.
Solution Approach 2:
The connection portions are designed with inherent compliance through elastic and plastic deformation capabilities, which act as a cushion against manufacturing tolerances. This beforehand cushioning allows for easier assembly by accommodating dimensional variations without requiring extremely tight tolerances, thereby reducing manufacturing complexity while maintaining connection reliability.
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
The stator can be easily and quickly assembled with reduced risk of damage due to the press-fit connection, which absorbs forces that might otherwise separate the teeth. This design also allows for tolerance compensation through deformation, reducing manufacturing requirements for the axle and enabling variable axle designs without affecting the stator.
Implementation Method 1
at least some of the individual teeth and, preferably, all of the individual teeth each have a radially inner pressing portion for elastic and/or plastic deformation and establishment of a press-fit connection
Implementation Method 2
at least some of the individual teeth and, preferably, all of the individual teeth each have a radially inner pressing portion for elastic and/or plastic deformation and establishment of a press-fit connection
Implementation Method 3
The pressing portion is designed to be elastically and/or plastically deformed when it is joined to the axle itself, with the forces occurring and acting on the individual tooth preferably not affecting the other portions of the individual tooth
Data Source
AI summary
A stator for an electric motor, wherein the stator has a laminated stator core which is formed from a multitude of individual teeth that can be arranged in a ring around an axis of rotation of the electric motor and interconnected in the circumferential direction, wherein each individual tooth of the plurality of individual teeth is flanked on both sides along the circumferential direction by a further individual tooth from among the plurality of individual teeth and has a connection portion for mechanically fixing the individual tooth to the individual teeth by which it is flanked, and wherein at least some of the individual teeth each have a pressing portion for elastic and/or plastic deformation and establishment of a press-fit connection between the laminated stator core and a radially inner axle, so that, upon joining of the stator to the axle, the stator can be fixed to the axle through the deformation of the pressing portions and a force acting on the axle as a result of the deformation between laminated stator core and axle.