Stepper Motor Stator Winding Segmentation
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Solution Overview
Problem
Existing stepper motors face challenges in reducing the number of coil winding steps, efficiently utilizing space, and preventing insulation failure due to adjacent windings, which complicates the winding process and reduces torque.
Innovation Solution
A stepper motor design where windings are wound around every other magnetic pole tooth, with the phase of unwound teeth shifted from those with windings, allowing for reduced coil winding steps, efficient space utilization, and preventing insulation failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If windings are wound around all the magnetic pole teeth of the stator, then the motor generates sufficient torque, but the number of coil winding steps increases and the winding process becomes complex
Solution Approach 1:
The patent applies segmentation by dividing the stator magnetic pole teeth into two groups: those with windings and those without windings. Specifically, windings are wound around every other magnetic pole tooth (e.g., teeth 31a, 31c, 31e, 31g have windings while 31b, 31d, 31f, 31h do not), thereby reducing the number of coil winding steps from 8 to 4 while maintaining torque generation capability through the phased arrangement of the unwound teeth
Solution Approach 2:
The patent applies local quality by creating different functional zones on the magnetic pole teeth. Some teeth (31a, 31c, 31e, 31g) have windings wound around them for torque generation, while other teeth (31b, 31d, 31f, 31h) are left unwound but have their tooth phases shifted to contribute to the magnetic field. This local differentiation reduces winding complexity while preserving motor performance
2Force
If windings are wound around all the magnetic pole teeth of the stator, then the motor generates sufficient torque, but the occupied space of the winding is not efficiently utilized
Solution Approach 1:
By segmenting the magnetic pole teeth into wound and unwound groups, the patent allows windings to be concentrated on specific teeth (31a, 31c, 31e, 31g) rather than distributed across all teeth. This concentration improves space utilization in the winding regions while the unwound teeth (31b, 31d, 31f, 31h) with shifted phases contribute to the magnetic field without occupying winding space
Solution Approach 2:
The patent introduces a phase shift dimension for the unwound teeth. The teeth without windings (31b, 31d, 31f, 31h) have their phases shifted relative to the wound teeth, creating a multi-dimensional magnetic field structure that maintains torque generation capability while freeing up spatial volume for more efficient winding packing in the designated winding regions
3Shape
If windings are wound around adjacent magnetic pole teeth, then the motor structure is compact, but insulation failure occurs due to adjacent windings
Solution Approach 1:
The patent segments the magnetic pole teeth into alternating wound and unwound groups, creating physical separation between adjacent windings. Windings are placed only on teeth 31a, 31c, 31e, 31g with teeth 31b, 31d, 31f, 31h left unwound between them, thereby eliminating the insulation failure issue caused by adjacent windings while preserving the compact overall motor structure
Solution Approach 2:
The unwound magnetic pole teeth (31b, 31d, 31f, 31h) serve as intermediary elements between the wound teeth. These intermediate teeth without windings act as physical barriers that separate adjacent windings, preventing insulation failure while still contributing to the magnetic field through their phased arrangement, thus maintaining compact structure without the harmful effects of adjacent windings
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
This design reduces the number of coil winding steps, enhances torque by efficient space utilization, and prevents insulation failure by eliminating adjacent windings, thereby simplifying the winding process and maintaining motor performance.
Implementation Method 1
a permanent magnet is arranged in the rotor... Current flows through the windings. This generates a rotating magnetic field, and rotates the rotor by a predetermined step angle
Implementation Method 2
Current flows through the windings. This generates a rotating magnetic field
Data Source
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AI summary
A stepper motor includes: a rotor (2) including a rotor core (21,22) and a permanent magnet (23), the rotor core (21,22) including a plurality of teeth (21A,22A); and a stator (3) arranged around the rotor (2) while being spaced apart from the rotor (2) and including a plurality of magnetic pole teeth (31), the magnetic pole teeth (31) including a plurality of sub-teeth (33) and projecting toward the rotor (2). A winding (40) is wound around every other magnetic pole tooth (31). The phase of the sub-teeth (33) on the magnetic pole teeth (31) carrying no winding is shifted from the phase of the sub-teeth (33) of the other magnetic pole teeth (31) comprising a winding (40).