Stator Tooth Keyed Assembly for Vibration-Resistant Air Gaps
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Solution Overview
Problem
Existing methods for fixing teeth in electric machines are bulky, unreliable, or poorly resistant to vibrations, which affects the performance and lifespan of axial flux electric machines due to variations in air gaps and asymmetries.
Innovation Solution
The use of keys, including a first key in a tooth keyway and a second key in a fixing support keyway, immobilized by an element that exerts a tensile force, allowing secure assembly without requiring significant space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fixing methods are used for teeth in axial flux electric machines, then the structure can be simple, but the fixing is bulky, unreliable, and poorly resistant to vibrations
Solution Approach 1:
The fixing means is divided into multiple keys (first key in tooth keyway, second key in fixing support keyway) that work together to secure the tooth. This segmentation allows each key to be optimized for its specific function while collectively providing reliable vibration resistance without requiring a single bulky fixing structure
Solution Approach 2:
The first key is partially housed in the tooth and partially housed in the fixing support, creating a nested arrangement where the keyway of the tooth is superimposed on the keyway of the fixing support. This nesting allows the keys to overlap and interlock, providing reliable fixing in a compact space
2Manufacturing precision
If traditional fixing methods are used, then assembly can be simple, but the fixing is not resistant to vibrations and leads to geometry errors
Solution Approach 1:
The keys are inserted into their respective keyways before the tooth is placed on the fixing support. This preliminary action ensures that the keys are properly positioned and aligned, allowing them to effectively resist vibrations once the tooth is secured, thereby maintaining air gap geometry precision
Solution Approach 2:
The keyways have inclined side walls that converge towards each other, creating a tapered or curved profile rather than straight parallel walls. This curvature helps the keys to wedge tightly when the tooth is placed and secured, providing vibration resistance while maintaining precise geometry
3Volume of moving object
If keys are used to fix teeth, then space efficiency is improved, but the assembly process becomes more complex requiring key insertion and immobilization steps
Solution Approach 1:
The fixing solution utilizes the radial dimension by having keys extend radially from the tooth into the fixing support. The keyways are arranged in superimposed positions, allowing keys to be inserted and secured in a radial direction rather than requiring axial or lateral space, thus achieving space efficiency
Solution Approach 2:
The keys act as intermediary elements between the tooth and the fixing support. Rather than directly connecting the two main components, the keys mediate the connection by fitting into keyways in both components and being immobilized together, simplifying the overall assembly while providing secure fixing
4Reliability
If multiple keys are used for fixing, then vibration resistance is improved, but the device complexity increases
Solution Approach 1:
The keys serve multiple functions: they transmit mechanical forces between the tooth and fixing support, resist vibrations through their interlocked arrangement, and maintain precise positioning through their keyed connection. This multi-functionality allows two keys to provide comprehensive fixing without requiring additional specialized components, thus improving vibration resistance without proportionally increasing complexity
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 solution provides a robust and space-efficient fixation of teeth, maintaining consistent air gaps and resisting vibratory stresses, thereby enhancing the performance and durability of the electric machine.
Implementation Method 1
the immobilising element includes a plastically deformable part which is integrally formed with the second key; the first key delimits a passage for the plastically deformable part, on the edge of which the plastically deformable part is designed to be crimped
Data Source
AI summary
A stator body for an electric machine, including: —at least one fixing support centered on a longitudinal axis, —teeth which are designed to accept coils of electrically conducting wire and which are uniformly distributed about the longitudinal axis, and—fixing means each suitable for fixing one of the teeth to the fixing support. Each fixing means includes: —at least one first key at least partially housed in a first keyway provided in the tooth, —at least one second key at least partially housed in a second keyway provided in the fixing support, and—at least one immobilizing element designed to immobilize the first key with respect to the second key.