Stator Yoke Recess Structure for Lightweight Motor Cores
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Solution Overview
Problem
Electric motorcycles require lightweight and compact electric motors without compromising power rating and robustness, as the limited space for batteries necessitates minimizing weight.
Innovation Solution
A stator core for electric motors is designed with recesses in the stator yoke and a support element with protrusions that interlock, using lighter materials like aluminum for the support element to reduce weight while maintaining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the stator core is made entirely of magnetic material, then the power rating and robustness are maintained, but the weight increases
Solution Approach 1:
The stator core is divided into two functional segments: a magnetic circuit portion (teeth and yoke) made of magnetic material for maintaining power rating, and a support portion made of lighter non-magnetic material for weight reduction. This segmentation allows each part to be optimized for its specific function while resolving the weight-strength contradiction.
Solution Approach 2:
Different materials are applied to different regions of the stator core based on local functional requirements. The magnetic circuit regions require high magnetic permeability material for efficient flux conduction, while the support regions can use lighter materials since they primarily provide mechanical support. This local differentiation resolves the contradiction by optimizing material selection for each specific location.
2Weight of moving object
If lighter non-magnetic material is used for the support portion, then the weight is reduced, but the thermal management capability deteriorates
Solution Approach 1:
The stator core is segmented into thermal management zones (magnetic circuit portions with windings) and structural support zones. The magnetic material portions act as heat sinks due to their high thermal conductivity, while the lighter support material provides structural integrity. This segmentation allows weight reduction in non-critical areas while maintaining thermal management in critical areas.
Solution Approach 2:
The magnetic circuit portions serve as intermediary thermal pathways between the windings and the external environment. These portions conduct heat away from the windings effectively, compensating for the lower thermal conductivity of the lighter support material, thus maintaining overall thermal management capability while reducing weight.
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 design achieves a lighter electric motor and motorcycle by reducing the stator core's weight through strategic material use and thermal management, enhancing performance without compromising power or robustness.
Implementation Method 1
The stator core is of magnetic material, such as of ferromagnetic material, for example, including iron
Implementation Method 2
a stator comprising one or more motor windings arranged for providing an electromagnetic coupling between the rotor and the stator
Data Source
AI summary
A stator core for an electric motor, the stator core being of magnetic material and defining a plurality of stator teeth and a stator yoke. The stator yoke comprises recesses at corresponding positions relative to, preferably at least most of, the plurality of teeth, the recesses being on the opposite side of the stator yoke relative to the plurality of teeth. An electric motor and an electric motorcycle are also disclosed in this document.