Stator Teeth Stack Bridge Removal for Flux Linkage
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Solution Overview
Problem
Conventional methods for producing stators for synchronous permanent magnet machines are costly and labor-intensive due to the need for complex interconnections between laminated teeth and yokes, which can lead to reduced flux linkage and efficiency.
Innovation Solution
A method involving a teeth stack with radially arranged teeth forming a circular structure, interconnected by bridges that are later removed, and inserted into a yoke stack with a sealing compound to form a solid unit, allowing for a simpler assembly and increased electromagnetic force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional methods use complex interconnections between laminated teeth and yokes, then structural stability is improved, but production cost and complexity increase significantly
Solution Approach 1:
The invention divides the stator into modular components: a yoke with yoke segments and a teeth stack with teeth segments. These segmented components can be manufactured separately and assembled together, simplifying production while maintaining structural stability through the modular design and interlocking segments.
Solution Approach 2:
The teeth stack and yoke are prepared in advance as separate pre-assembled units with their respective segments and connections already in place. This preliminary preparation allows for easier final assembly and reduces production complexity during the main assembly process.
2Stability of the object's composition
If conventional methods use complex interconnections between laminated teeth and yokes, then structural stability is improved, but production time increases
Solution Approach 1:
By segmenting the teeth and yoke into separate manufacturable units that can be produced independently and assembled efficiently, the invention reduces production time while maintaining the structural stability needed for motor operation.
3Strength
If bridges are used to interconnect adjacent teeth, then mechanical strength is improved, but flux linkage is reduced due to short-circuiting
Solution Approach 1:
The invention removes or extracts the bridges that interconnect adjacent teeth, eliminating the harmful short-circuiting effect that reduces flux linkage. The teeth are left as separate entities, improving electromagnetic performance while maintaining structural integrity through alternative design features.
4Stability of the object's composition
If conventional assembly methods are used, then structural integrity is maintained, but assembly complexity increases
Solution Approach 1:
The segmented design allows the stator to be assembled from discrete, pre-prepared components (yoke segments and teeth segments) that can be easily positioned and connected, simplifying the assembly process while maintaining structural integrity through the modular construction.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E
AI summary
The invention relates to a method for producing a stator (100, 300, 400) for a synchronous permanent magnet machine, the method comprising a step of providing a teeth stack (110) comprising several teeth (111), wherein the teeth (111) are arranged in a radial direction forming the teeth stack (110) as a circular structure, wherein the teeth (111) each comprise a root end (113) in a radially outward direction of the teeth stack (110) and an inner end (115) in a radially inward direction of the teeth stack (110) and wherein each two adjacent teeth (111) form a gap (111a) in-between and wherein the inner ends (115) of the adjacent teeth (111) are interconnected by means of bridges (114); and a step of providing at least one coil (130, 430) in at least one of the gaps (111a) between adjacent teeth (111) of the teeth stack (110). The method further comprises a step of arranging the teeth stack (110) within a yoke stack (120, 320, 420) such that the root ends (113) of the teeth (111) are in mechanical contact with the yoke stack (120, 320, 420), and a step of removing at least a part of the bridges (114) at the inner end (115) of the teeth (111) such that the teeth stack (110) has a predetermined diameter (152) in the radially inward direction. The invention further relates to a stator (100, 300, 400), a teeth stack (110) and a synchronous permanent magnet machine having a stator (100, 300, 400).