Stator Unit Serial Winding via Split Core Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current motor designs face challenges in implementing serial winding due to limitations in core configuration, leading to reduced mass productivity, performance degradation, and increased investment costs, particularly when using split cores or unfolding cores.
Innovation Solution
A stator unit with a unit stator core featuring three protruding teeth and notches, allowing for serial winding of coils, which improves mass productivity and prevents performance degradation by enabling efficient coil winding and minimizing bus bar size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If split cores are used to form the stator, then the stator can be assembled, but mass productivity decreases because serial circuit implementation becomes difficult
Solution Approach 1:
The stator core is divided into multiple split cores that can be assembled separately, but the coil winding is designed to connect these split cores in series through continuous winding across the air gap, enabling both easy assembly and serial circuit implementation
Solution Approach 2:
The coil acts as an intermediary element that bridges the split cores across the air gap, electrically connecting them in series while mechanically allowing separate assembly of the stator core components
2Ease of manufacture
If bus bar is used to implement serial circuit, then electrical connection is achieved, but core stack decreases and performance is degraded
Solution Approach 1:
The bus bar is extracted from the design and replaced with direct coil winding connections across the air gap, eliminating the need for separate bus bar components and maintaining full core stack height for optimal performance
Solution Approach 2:
The electrical connection function previously performed by the bus bar is merged into the coil winding structure itself, which directly connects the split cores in series through the air gap without requiring additional components
3Ease of manufacture
If unfolding core is used, then stator can be formed, but three nozzle winding cannot be implemented due to core characteristics, causing investment cost to increase
Solution Approach 1:
The coil winding extends into the radial dimension by crossing the air gap to reach adjacent split cores, enabling three-nozzle simultaneous winding operations that would be impossible with conventional unfolding core structures
4Ease of manufacture
If both ends of unfolding core are connected to form stator, then stator is complete, but height difference between both ends occurs during molding, reducing assemblability and degrading performance
Solution Approach 1:
The stator core is segmented into multiple split cores of uniform height that can be molded separately with consistent dimensions, eliminating the height difference problem that occurs when molding a single large unfolding core
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 configuration enables efficient serial winding, reduces investment costs, minimizes noise and vibration, and enhances motor reliability by allowing individual winding and easier maintenance.
Implementation Method 1
a coil configured to form a rotating magnetic field is wound around the stator and causes electrical interaction with the rotor to induce rotation of the rotor
Data Source
AI summary
Embodiments relate to a stator unit, a stator, and a motor comprising same, the stator unit comprising: a unit stator core; an insulator disposed on the unit stator core; and a coil wound on the insulator, wherein the unit stator core comprises a main body formed so as to have a prescribed curvature with reference to the centre, and three teeth formed so as to protrude toward the centre from the main body, the main body comprising notches formed between the teeth. Thus mass productivity can be increased as a result of series winding using a coil on a unit stator core having three teeth arranged thereon.