Varying Insulative Density Stator Design for Electric Machine Torque
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Solution Overview
Problem
Conventional electric machine components face inefficiencies due to uniform core material thickness, which compromises between cost, losses, and torque capability, and fail to effectively manage non-uniform core loss distributions, impacting performance.
Innovation Solution
Additive manufacturing is used to selectively print discrete portions of electrical steel and insulating material, with denser insulation in high-loss areas and coarser spacing elsewhere, simulating thin laminations to reduce reluctance and enhance torque capability, while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform core material thickness is used, then manufacturing is simpler and cost is reduced, but core losses increase and torque capability is compromised
Solution Approach 1:
The patent applies local quality by varying the thickness of the core material and insulation distribution across different regions of the stator and rotor. Specifically, the teeth regions have different core material thickness compared to the outer periphery, allowing optimization of each region for its specific function - teeth for torque generation and outer periphery for magnetic flux management.
Solution Approach 2:
The patent segments the core structure into distinct regions (teeth and outer periphery) with different material properties and thicknesses. This segmentation allows independent optimization of each region, with the teeth having optimized core material thickness for torque capability and the outer periphery having appropriate thickness for reducing core losses.
2Ease of manufacture
If uniform core material thickness is used, then manufacturing is simpler, but torque capability is compromised
Solution Approach 1:
The patent enhances torque capability by optimizing the core material thickness specifically in the teeth regions where torque is generated. The teeth have increased core material volume compared to conventional uniform designs, which directly improves the torque-producing capability while the outer periphery maintains appropriate thickness for overall structural integrity.
3Loss of energy
If denser insulation is printed in high-loss areas, then core losses are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent changes the insulation parameters (density and distribution) based on the specific requirements of different regions. The additive manufacturing process enables precise control of insulation material deposition, allowing denser insulation in high-loss areas such as the teeth while using coarser spacing in lower-loss areas, thereby reducing core losses without requiring complete uniform densification.
Solution Approach 2:
The patent applies local quality to insulation distribution by making the insulation density and spacing vary across different regions of the stator and rotor. High-loss areas receive denser insulation with smaller cell volumes, while lower-loss areas have coarser insulation spacing, optimizing loss reduction where needed while maintaining manufacturing efficiency elsewhere.
4Force
If varying insulative density is implemented, then reluctance is optimized and torque is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes parameter changes by varying the insulation cell volume and spacing according to the specific requirements of different regions. The additive manufacturing process allows precise control of these parameters, creating smaller insulation cells in teeth regions to reduce reluctance and enhance torque, while using larger cells in outer periphery regions where the requirements are different.
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 approach reduces core losses and improves performance by optimizing the distribution of insulating material, achieving higher torque and reduced reluctance without increasing overall material costs.
Implementation Method 1
A volume of the discrete cells within the outer periphery is greater than a volume of the discrete cells within the teeth such that a reluctance of the teeth is greater than a reluctance of the outer periphery
Data Source
AI summary
An electric machine includes a plurality of printed layers arranged to form a stator having an outer periphery and teeth extending radially inward from the outer periphery. Each of the printed layers includes discrete portions of metal and discrete portions of insulation. The discrete portions of insulation define a contiguous network of insulative boundaries separating discrete cells formed by the discrete portions of the metal. A volume of the discrete cells within the outer periphery is greater than a volume of the discrete cells within the teeth such that a reluctance of the teeth is greater than a reluctance of the outer periphery.