Wound Stator Core Segmented Layer Design
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Solution Overview
Problem
Current methods for manufacturing stator cores for axial-flux motors face challenges such as material waste, high energy consumption, and limited production efficiency due to the need for precise coordination of spiral winding and teeth/stamp design, which also result in high defect rates and prolonged production times.
Innovation Solution
A wound stator core design featuring a spirally piled strip with alternating teeth and slots, where each tooth is connected by a dental part to ensure precise alignment and allow for simultaneous winding and formation of two stators, reducing material waste and energy consumption by eliminating the need for additional grinding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a silicon steel strip is stamped with teeth and slots while being spirally wound, then a stator core can be formed, but precise coordination and control are required to ensure teeth and slots are formed with continuously varying pitches and aligned precisely, increasing device complexity and manufacturing difficulty
Solution Approach 1:
The stator core is divided into multiple layers with different slot numbers (e.g., first layer with 12 slots, second layer with 10 slots). Each layer is independently formed with its own tooth and slot configuration, allowing precise alignment within each layer while reducing the overall coordination complexity across the entire stator core.
Solution Approach 2:
The patent transitions from a single-layer stator design to a multi-layer stacked configuration. By adding the dimensional aspect of layer stacking, the design achieves continuously varying pitches through different layer combinations while maintaining precise alignment within each layer, thereby resolving the contradiction between productivity and device complexity.
2Manufacturing precision
If an additional grinding process is used to modify tooth top profiles after spirally winding, then desired tooth shapes can be achieved, but material loss increases and energy consumption and work hours increase
Solution Approach 1:
The tooth top profiles are designed and formed during the initial stamping and spirally winding process rather than being modified afterward. The stamping模具 (mold) is designed to directly create the desired tooth top shapes (flat, rounded, or pointed) during winding, eliminating the need for subsequent grinding operations and thereby reducing material loss while maintaining manufacturing precision.
Solution Approach 2:
The unnecessary grinding step is extracted and removed from the manufacturing process. By designing the stamping and winding system to directly produce the required tooth profiles, the patent eliminates the harmful additional process that causes material loss and increased energy consumption, while still achieving the desired manufacturing precision.
3Manufacturing precision
If teeth and slots are formed with continuously varying pitches to ensure precise alignment, then slot straightness is maintained, but the coordination and control requirements increase production time and defect rates
Solution Approach 1:
The stator core is segmented into multiple layers, each with fixed pitch configurations. This segmentation allows slot straightness to be maintained within each layer through precise alignment during stacking, while avoiding the need for continuously varying pitches across the entire core, thereby reducing coordination complexity and production time.
Solution Approach 2:
The patent solves the pitch variation requirement by transitioning to a multi-layer stacked structure. Instead of varying pitches continuously within a single layer (which increases production complexity), the design achieves the effect through discrete layer stacking with different slot numbers and configurations, maintaining slot straightness while reducing production time and defect rates.
4Productivity
If a multi-layer stator core with different slot numbers is designed, then two stators can be wound and formed simultaneously improving productivity, but the alignment precision between layers becomes more difficult to maintain
Solution Approach 1:
The stator core is divided into distinct layers with clearly defined interfaces. Each layer is independently formed and then stacked, with alignment features designed at the interfaces to ensure precise positioning. This segmentation approach enables simultaneous winding of multiple stators while maintaining alignment precision through modular assembly.
Solution Approach 2:
The patent uses the vertical stacking dimension to achieve multi-stator production. By designing layers with different slot numbers that stack vertically, the system enables simultaneous formation of multiple stators with varying configurations while maintaining alignment precision through the structured layering approach and interface design.
Data Source
AI summary
A wound stator core disclosed is substantially formed from a spirally piled strip. In an embodiment, the strip with a specific length is formed with a first dentition and a second dentition, whereas the first dentition is featured by a first slot-number ratio and is composed of a first side and a plurality of first teeth in a manner that the plural first teeth are arranged as an array on the first side; which is also same to the second dentition while allowing the second slot-number ratio to be equal to the first slot-number ratio. In addition, each first tooth is formed with a first dental part at a free end thereof, while also each second tooth is formed with a second dental part at a free end thereof, and the first dental part of each first tooth is connected to the second dental part of its corresponding second tooth.