Tunable Insert Ring for Stator Vibration Control
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Solution Overview
Problem
Electromagnetic machines, such as electric motors and generators, face challenges with vibration, noise, and efficiency losses due to the interaction between the rotor and stator, which are not adequately addressed by existing technologies.
Innovation Solution
A tunable insert ring is introduced between the motor housing and stator, featuring projections that contact the stator and motor housing with a controllable spring rate, providing stiffness and minimizing vibration while defining cooling channels, thus enhancing the structural integrity and thermal management of the electromagnetic machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional mounting methods (shrink-fitting, resin-bonding) are used to secure the stator, then structural stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The insert ring is divided into multiple segments or quadrants that can be independently positioned and secured. Each segment includes features like protrusions, recesses, or cooling channels that can be independently optimized. This segmentation allows for simplified assembly where the insert ring can be installed as modular components rather than requiring complex monolithic mounting processes.
Solution Approach 2:
The insert ring serves as an intermediary component between the stator and motor housing. Rather than directly mounting the stator to the housing using complex shrink-fitting or resin-bonding processes, the insert ring acts as a mediator that simplifies the connection. The insert ring includes features like protrusions that engage with mounting ears and recesses that receive the stator, creating a simplified intermediate mounting structure.
2Stability of the object's composition
If the stator is rigidly mounted to minimize vibration, then structural stability is improved, but thermal management capability deteriorates
Solution Approach 1:
The insert ring incorporates localized features with different functional properties. Specifically, the insert ring includes protrusions that contact the stator at discrete locations to provide mechanical stability and vibration reduction, while simultaneously incorporating cooling channels in specific regions to enable thermal management. This local differentiation allows the same component to fulfill both mechanical and thermal functions without compromise.
Solution Approach 2:
The insert ring is designed as a multi-functional component that simultaneously performs mechanical mounting, vibration reduction, and thermal management functions. Rather than requiring separate components for each function, the insert ring integrates features like protrusions for mechanical engagement, recesses for stator positioning, and cooling channels for thermal management, all within a single component that secures the stator.
3Temperature
If cooling channels are added to improve thermal management, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling channels are merged into the insert ring structure itself rather than being separate components. The insert ring is formed as a single integrated piece that includes protrusions for mechanical engagement, recesses for stator positioning, and cooling channels for thermal management all combined in one component. This merging eliminates the need for separate cooling system components and reduces overall structural complexity.
Solution Approach 2:
The insert ring serves multiple functions simultaneously: mechanical mounting via protrusions and recesses, vibration reduction through compliant material properties, and thermal management through integrated cooling channels. By consolidating these multiple functions into a single universal component, the design avoids the complexity that would arise from adding separate systems for each function.
4Stability of the object's composition
If compliant material with high damping is used to reduce vibration, then vibration reduction is improved, but structural stiffness deteriorates
Solution Approach 1:
The insert ring uses compliant material with high damping properties locally at the interfaces where it contacts the stator and motor housing to absorb vibrations. However, the insert ring maintains sufficient structural stiffness in its overall geometry and feature design (protrusions, recesses, cooling channels) to provide stable mechanical mounting. This local application of compliance where needed while maintaining global structural integrity resolves the contradiction between vibration reduction and structural stiffness.
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 effectively reduces vibration and noise, improves efficiency, and eliminates the need for costly manufacturing steps like shrink-fitting and resin-bonding, making the electromagnetic machine more economical and scalable for various applications.
Implementation Method 1
minimize vibration of the stator within the motor housing
Implementation Method 2
Each of the plurality of projections may have a location on the tunable insert ring and a spring rate. At least one of the spring rate and the location is tunable to thereby reduce vibration of the stator within the motor housing.
Implementation Method 3
The tunable insert ring may contact the motor housing and the stator with an interference fit.
Implementation Method 4
The tunable insert ring and the stator define at least one cooling channel therebetween.
Data Source
AI summary
An electromagnetic machine includes a motor housing defining a cavity therein, and a stator disposed within the cavity. The stator has an external surface and a plurality of mounting ears each configured to receive a fastener and extending from the external surface towards the motor housing. The assembly includes a tunable insert ring disposed between the motor housing and the stator. The tunable insert ring and the stator define at least one cooling channel therebetween. The tunable insert ring encircles the external surface and includes a plurality of projections each extending towards and disposed in contact with the stator to thereby stiffen the electromagnetic machine and minimize vibration of the stator within the motor housing. A device including the electromagnetic machine is also described.