Welded Stator Frame Cast Iron Steel Bar Design
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Solution Overview
Problem
Existing motor stator frames are either heavy and bulky when made in a single piece of cast iron or costly and prone to distortions when constructed from multiple welded steel parts, which can lead to operational issues like hot spots and magnetic unbalance.
Innovation Solution
A motor stator frame design featuring cast iron plates with steel inserts and chamfered edges for welding, allowing for a lighter, less expensive structure with reduced distortion risks, where the steel bars are welded to the inserts within the plates, and the welds are planar and flush with the outer faces to minimize distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the frame is made in a single piece of cast iron, then the frame is more rigid and solid, but the frame becomes heavy and bulky
Solution Approach 1:
The frame is divided into multiple components: cast iron plates for the end structures and steel bars for the connecting elements. This segmentation allows each part to be optimized for its specific function - the plates provide rigidity where needed while the bars provide structural connection with less mass, thereby reducing overall frame mass while maintaining necessary strength.
2Weight of stationary object
If multiple welded steel parts are used to reduce mass, then the frame mass is reduced, but the frame becomes prone to distortions under internal stresses
Solution Approach 1:
Steel inserts are introduced as intermediary elements between the cast iron plates and steel bars. These inserts are embedded within the cast iron plates and provide dedicated welding surfaces. This intermediary structure allows the welds to be contained in specific localized zones rather than across large plate surfaces, reducing the overall distortion risk while maintaining the mass reduction benefits of a multi-part construction.
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 balance of reduced bulkiness and cost-effectiveness while minimizing distortions during cooling, ensuring proper motor operation by maintaining structural integrity and reducing the risk of hot spots and magnetic imbalances.
Implementation Method 1
each plate in cast iron has at least one orifice receiving a steel insert, the end of the bar attached to the plate being welded to said insert
Data Source
AI summary
The invention relates to a motor stator frame having two plates in cast iron; at least one steel bar connecting both plates, the bar having two ends each attached to one of the plates; and each plate in cast iron has at least one orifice receiving an insert in steel, the end of the bar attached to the plate being welded to said insert.