Two-Part Stator Design for High Copper Fill Factor
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Solution Overview
Problem
Existing stator designs for external rotor motors suffer from low copper fill factors, high handling complexity, and increased costs due to complex pole shoe configurations and the need for individual coil winding, which also result in high detent torque and noise.
Innovation Solution
A two-part stator construction with a stator ring and individually wound poles, allowing for high flexibility and reduced material wastage, with a focus on minimizing detent torque and simplifying the winding process by using a flexible connecting web and bending zones, enabling a higher copper fill factor and lower manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If needle winding is used with a wide needle to guide thick wires, then low-voltage motors can achieve low number of turns and inductance, but winding space is lost and copper fill factor is limited to 30-35%
Solution Approach 1:
The stator is divided into multiple individual teeth that are separately wound and then assembled together. Each tooth can be independently wound with optimal wire placement, eliminating the need for a wide guiding needle and maximizing copper fill factor while reducing winding space losses.
Solution Approach 2:
The invention transitions from a conventional single-piece stator wound in three dimensions with spatial constraints to a modular assembly of individual teeth that can be wound separately and then assembled. This dimensional reorganization allows optimal wire packing in each tooth without the constraints of a wide needle guide.
2Quantity of substance
If individual teeth with dovetails are used to achieve better copper fill factors, then winding space utilization improves, but handling complexity and manufacturing costs increase due to punched grids and assembly requirements
Solution Approach 1:
The stator is segmented into individual teeth that are pre-wound and then assembled using simple form-fitting connections without requiring complex punched grids or extensive handling equipment. The segmentation enables optimized winding in each tooth while simplifying the overall assembly process.
Solution Approach 2:
The invention replaces expensive and complex punched grids with simple, inexpensive form-fitting connection elements that facilitate assembly of individual teeth. These connection elements are easy to manufacture and install, significantly reducing manufacturing costs while maintaining high copper fill factors.
3Adaptability or versatility
If complex pole shoe configurations are used to deactivate individual coils with insulating bodies, then coil deactivation capability is achieved, but manufacturing complexity and costs increase significantly
Solution Approach 1:
The stator is divided into individual teeth, each with its own winding. This segmentation allows individual coils to be deactivated by simply removing or isolating the affected tooth from the magnetic circuit, eliminating the need for complex insulating body configurations within pole shoes.
Solution Approach 2:
The invention extracts the coil deactivation function from the complex pole shoe structure and implements it at the individual tooth level. Each tooth can be independently removed or isolated, providing simple and effective coil deactivation without requiring complex insulating structures within the pole shoes.
4Device complexity
If conventional stator designs are used for external rotor motors, then structural simplicity is maintained, but detent torque is high resulting in increased noise
Solution Approach 1:
The stator is segmented into individual teeth with optimized magnetic pole configurations. This segmentation allows the magnetic poles to be precisely positioned and shaped to minimize detent torque while maintaining structural simplicity. The individual teeth can be arranged to create optimal magnetic flux distribution that reduces noise and vibration.
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 two-part stator design achieves a higher copper fill factor, reduces handling complexity and material wastage, lowers tolerance sensitivity, and decreases detent torque, thereby improving motor performance and reducing noise while maintaining low manufacturing costs.
Implementation Method 1
the flux of the permanent magnets can be conducted more effectively into the stator
Implementation Method 2
stator for a polyphase machine
Data Source
AI summary
The invention relates to a stator with a plurality of field coils, wherein the yoke teeth, which bear the field coils, of the poles are connected with their free ends to a stator ring, and wherein adjacent pole shoes or poles are connected to one another.