System and method for magnetizing rare earth metals to build rotor assembly

Abstract

A system 101 for magnetizing one or more rare earth metals 110 includes one or more laminates 114. The one or more laminates 114 are stacked together to build a laminate 116. The one or more stacked laminate blocks 116 are stacked together to construct the rotor assembly 100. The rotor assembly 100 includes one or more surfaces 118 on an outer periphery 120. The rotor assembly 100 includes one or more slots 102 that provide a predetermined space to position one or more rare earth metals 110 in a non-magnetized state. The system 101 further comprises a magnetization unit 122. The magnetizing unit 122 comprises one or more magnetizing surfaces 124 and one or more magnetizing windings 126. The one or more magnetization surfaces 124 magnetize the one or more rare earth metals 110 of the rotor assembly 100 by delivering a predetermined power supply.

Description

Technical Field

[0001] Embodiments of the present disclosure generally relate to a rotor assembly of an electric machine, and more particularly, to systems and methods for magnetizing one or more rare earth metals to construct a rotor assembly of an electric machine. This application claims priority to Indian Provisional Application No. 202241070714, filed on Dec. 7, 2022, the disclosure of which is incorporated herein by reference. Background Art

[0002] Today, automotive manufacturers, especially those specializing in electric vehicles, particularly electric vehicle manufacturers, prefer permanent magnet (PM) motors because of their extremely high starting torque. In PM motors, the rotor windings are replaced by permanent magnets as they require a continuous supply of electrical energy to generate and maintain a magnetic field. Additionally, the complex and challenging structure of the rotor windings requires extremely high precision when inserted into the magnetic slots of the rotor assembly.

[0003] Traditionally, when assembling the rotor assembly of a PM motor, permanent magnets (which are magnetized in advance) are inserted into multiple slots of the rotor assembly. The multiple slots are positioned around the rotor shaft of the rotor assembly and serve as a housing for the permanent magnets. Since the rotor assembly is a magnetic material, the permanent magnets are attracted to the rotor assembly, so assembling the permanent magnets into the rotor assembly is a complex task, which may ultimately lead to operator fatigue. The assembly process requires a large number of automotive tools and techniques (for fixing and pressing) to perfectly place the permanent magnets in the multiple slots, which will increase the cost and complexity of the system.

[0004] Permanent magnets are very sensitive to heat and vibration. When the permanent magnets are heated, the permanent magnets will demagnetize. Therefore, additional attention needs to be paid to the permanent magnets, which makes the transportation and handling processes difficult. During assembly, it is possible to place the permanent magnets in the incorrect magnetic pole direction, so trained professionals are required. Additionally, an additional mechanism is needed to separate the permanent magnets.

[0005] In existing systems, automotive manufacturers avoid using permanent magnets (which are magnetized in advance) in the rotor assembly of an electric machine. Instead of using permanent magnets, automotive manufacturers fill the magnetic slots of the rotor assembly with a liquid magnetic material and mold it. At the same time, filling and molding the liquid magnetic material requires a molding machine (such as an injection molding machine), which makes the system more costly. Additionally, when filling and molding the liquid magnetic material, many parameters (such as orientation strength, application time, and application method) need to be noted.

[0006] In other existing systems, the rotor assembly is constructed as a single part, which results in high eddy current losses. In other existing systems, due to the heat generated by the rotation of the rotor assembly, the magnetic force of the permanent magnet weakens. In other existing systems, due to the brittleness of the magnet, the rotor assembly is constructed as one or more parts, and then the one or more parts are assembled to construct the rotor assembly. In this method, it is difficult to position the same magnetic poles (N-N or S-S) of the magnets together along the longitudinal axis of the rotor assembly.

[0007] In addition, in other existing systems, automobile manufacturers use a multi-step magnetization method, in which all north poles (N) will be magnetized in different magnetization steps, and all south poles (S) will be magnetized in different magnetization steps. Multi-step magnetization results in uneven Tesla values for the north (N) and south (S) poles of the rotor assembly. A rotor assembly with uneven Tesla values will cause polarization imbalance, wear problems, voltage harmonics, and low efficiency. In addition, the uneven Tesla values may cause torque variations in the rotor assembly, so the torque variations in the rotor assembly may generate vibrations. Traditional and existing systems are not sufficient to solve the above problems of constructing an electric motor.

[0008] Therefore, there is still a need for an improved system and method for magnetizing one or more rare earth metals to construct the rotor assembly of an electric motor, so as to solve the above problems. Summary of the Invention

[0009] In view of the above, one embodiment of the present disclosure provides a system for magnetizing one or more rare earth metals to construct a rotor assembly. The system includes one or more laminates. The one or more laminates are stacked together to construct a laminated block. The one or more laminated blocks are stacked together to construct a rotor assembly. The rotor assembly includes one or more surfaces on the outer periphery of the rotor assembly. The rotor assembly includes one or more slots that are mechanically configured to provide a predetermined space for positioning one or more rare earth metals in a non-magnetized state. The system further includes a magnetization unit. The magnetization unit includes one or more magnetization surfaces and one or more magnetization windings. The one or more magnetization surfaces are configured to magnetize one or more rare earth metals of the rotor assembly by delivering a predetermined power supply through the one or more magnetization windings.

[0010] In one embodiment, the one or more magnetization windings include different polarities. The one or more magnetization windings having different polarities are configured to magnetize one or more rare earth metals in a manner such that one or more adjacent magnetic poles of the rotor assembly are opposite (N-S, S-N).

[0011] In another embodiment, one or more surfaces of the rotor assembly include a first predetermined shape. One or more magnetization surfaces of the magnetization unit include a second predetermined shape.

[0012] In another embodiment, the first predetermined shape and the second predetermined shape are constructed in a way that they are positioned relative to each other to avoid misalignment between the rotor assembly and the magnetization unit.

[0013] In another embodiment, one or more surfaces of the rotor assembly are positioned at a predetermined distance from one or more magnetization surfaces of the magnetization unit.

[0014] In another embodiment, the predetermined distance varies based on the outer periphery of the rotor assembly, the positioning of the first predetermined shape of one or more surfaces and the second predetermined shape of one or more magnetization surfaces, and the orientation of one or more rare earth metals.

[0015] In another embodiment, the magnetization unit further includes one or more flux concentrators. The one or more flux concentrators are configured to separate one or more magnetization surfaces of the north pole (N) and one or more magnetization surfaces of the south pole (S). One or more surfaces of the rotor assembly, the one or more flux concentrators, and one or more magnetization surfaces of the magnetization unit are configured to converge magnetic flux lines from the magnetization unit to one or more rare earth metals located on one or more slots of the rotor assembly. In another embodiment, the magnetization unit is configured to magnetize one or more rare earth metals of the rotor assembly (100) evenly at one time in a way that one or more adjacent magnetic poles of the rotor assembly (100) are opposite (N-S, S-N).

[0016] In another aspect, a method of magnetizing one or more rare earth metals to construct a rotor assembly is provided. The method includes the following steps: (a) stacking one or more laminates together to construct a laminated block; (b) positioning one or more rare earth metals into one or more slots; (c) bonding one or more rare earth metals to the one or more slots; (d) stacking one or more laminated blocks using one or more joining processes in the presence of a rotor shaft to construct a rotor assembly having one or more balance rings; (e) balancing the rotor assembly including one or more surfaces on the outer periphery; (f) setting the rotor assembly into a magnetization unit that includes one or more magnetization surfaces and one or more magnetization windings; (g) correspondingly positioning the first predetermined shape and the second predetermined shape together in a way that avoids misalignment between the rotor assembly and the magnetization unit; (h) positioning one or more surfaces of the rotor assembly at a predetermined distance from one or more magnetization surfaces of the magnetization unit; (i) using one or more surfaces of the rotor assembly, one or more flux concentrators, and one or more magnetization surfaces of the magnetization unit to converge magnetic flux lines from the magnetization unit to one or more rare earth metals; and (j) magnetizing one or more rare earth metals by delivering a predetermined power supply through one or more magnetization windings.

[0017] In another embodiment, the method further comprises the steps of: using one or more magnetization windings having different polarities to magnetize one or more rare earth metals in a manner opposite to one or more adjacent magnetic poles (N-S, S-N) of the rotor assembly.

[0018] In another embodiment, the method further comprises the steps of: using one or more flux concentrators to separate one or more magnetized surfaces of the north pole (N) and one or more magnetized surfaces of the south pole (N).

[0019] In another embodiment, the method further comprises the steps of: using a magnetization unit to uniformly magnetize one or more rare earth metals of the rotor assembly all at once in a manner opposite to one or more adjacent magnetic poles (N-S, S-N) of the rotor assembly (100). In another embodiment, one or more joining processes include a riveting process, a welding process, a clamping process, an interlocking process, an adhesive process, and a fastening process. These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the drawings. However, it should be understood that the following description, while indicating preferred embodiments and many of their specific details, is given by way of illustration only and not limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit of the embodiments herein, and the embodiments herein include all such modifications. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Embodiments herein will be better understood from the following detailed description with reference to the accompanying drawings, in which:

[0021] Figure 1A A system for magnetizing one or more rare earth metals to construct a rotor assembly according to an embodiment herein is shown;

[0022] Figure 1B A top view of a rotor assembly having a magnetization unit according to an embodiment herein is shown;

[0023] Figure 1C A partial schematic cross-sectional view of a rotor assembly having a magnetization unit according to an embodiment herein is shown;

[0024] Figure 2A A top view of a laminate of one or more laminates of a rotor assembly according to an embodiment herein is shown;

[0025] Figure 2B An isometric view of a laminated block of a rotor assembly according to an embodiment herein is shown;

[0026] Figure 2C An isometric view of one or more laminated blocks of a rotor assembly according to an embodiment herein is shown;

[0027] Figure 3Shows an exploded view of the electric motor of the system according to an embodiment herein; and

[0028] Figure 4A and Figure 4B Shows a method for magnetizing one or more rare earth metals to construct the rotor assembly of FIG. 1 according to an embodiment herein. Detailed Description

[0029] In the following description, for purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. However, it will be apparent that embodiments of the present disclosure may be practiced without these specific details. Several features described below may each be used independently of one another or in any combination with other features. A single feature may not solve all of the problems discussed above, nor may it solve only some of the problems discussed above. Any feature described herein may not fully solve some of the problems discussed above.

[0030] The following description provides only exemplary embodiments and is not intended to limit the scope, applicability, or construction of the present disclosure. Instead, the following described exemplary embodiments will provide those skilled in the art with a description enabling the practice of the exemplary embodiments. It should be understood that various changes may be made to the functions and arrangements of the elements without departing from the spirit and scope of the present disclosure as set forth.

[0031] The words "exemplary" and / or "illustrative" mean used as an example, instance, or illustration herein. To avoid doubt, the subject matter disclosed herein is not limited by these examples. Additionally, any aspect or design described herein as "exemplary" and / or "illustrative" is not necessarily to be construed as superior or advantageous to other aspects or designs, nor does it mean excluding equivalent exemplary structures and techniques known to those of ordinary skill in the art. Further, if the terms "comprising," "having," "including," and other similar words are used in the detailed description or claims, such terms are intended to be inclusive - in a manner similar to the term "including" as an open transitional word - and do not exclude any additional or other elements.

[0032] Reference to "an embodiment" or "embodiments," "instance" or "an instance" throughout this specification means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases "in an embodiment" or "in embodiments" in various places throughout this specification are not necessarily all referring to the same embodiment. Additionally, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0033] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the present disclosure. Unless the context clearly dictates otherwise, the singular forms "a", "an", and "the" used herein also include the plural forms. It should be further understood that the terms "comprises" and / or "comprising", when used in this specification, specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0034] The drawings are used to assist in easily understanding the various technical features, and it should be understood that the embodiments presented herein are not limited by the drawings. Accordingly, the present disclosure should be construed as extending to any alterations, equivalents, and substitutions other than those specifically set forth in the drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.

[0035] Accordingly, the embodiments herein disclose a system for magnetizing one or more rare earth metals to construct a rotor assembly. The system includes one or more laminates. One or more laminates are stacked together to construct a laminated block. One or more laminated blocks are stacked together to construct a rotor assembly. The rotor assembly includes one or more surfaces on the outer periphery of the rotor assembly. The rotor assembly includes one or more slots that are mechanically configured to provide a predetermined space for positioning one or more rare earth metals in a non-magnetized state.

[0036] The system includes a magnetization unit. The magnetization unit includes one or more magnetization surfaces and one or more magnetization windings. One or more magnetization surfaces are configured to magnetize one or more rare earth metals of the rotor assembly by delivering a predetermined power supply using one or more magnetization windings.

[0037] Reference is now made to the drawings, and more particularly to FIGS. 1 through 4, which show preferred embodiments, wherein like reference numerals consistently denote corresponding features throughout the figures.

[0038] Figure 1AShown is a system 101 for magnetizing one or more rare earth metals 110 to construct a rotor assembly 100 according to an embodiment herein. The system 101 includes one or more laminates 114. One or more laminates 114 are stacked together using one or more connecting devices. Each of the one or more laminates 114 includes one or more connecting devices. The one or more connecting devices are configured to stack the one or more laminates 114 together. The one or more laminates 114 are stacked together to construct a laminated block 116. One or more laminated blocks 116 are stacked together to construct the rotor assembly 100.

[0039] The rotor assembly 100 includes one or more slots 102, one or more weight relief cuts 104, one or more balance rings 106, and a shaft slot 108. The one or more slots 102 are mechanically configured to provide a predetermined space for positioning one or more rare earth metals in a non-magnetized state. In one embodiment, the number and size of the one or more slots 102 may vary according to the output requirements of the motor. In one embodiment, the motor may include, but is not limited to, a mid-drive motor and a hub motor. In another embodiment, the motor may include, but is not limited to, an interior permanent magnet (IPM) motor and a surface permanent magnet (SPM) motor.

[0040] One or more weight relief cuts 104 are positioned at predetermined locations on the rotor assembly 100 to reduce the weight of the rotor assembly 100. In one embodiment, the predetermined locations of the one or more weight relief cuts 104 may be the axial and longitudinal surfaces of the rotor assembly. One or more rare earth metals 110 may be inserted into one or more slots of the one or more laminated blocks 116. In another embodiment, the shape of the one or more rare earth metals may include, but is not limited to, plates, rods, or cylinders. In another embodiment, the one or more rare earth metals may be solid or liquid. The rotor assembly 100 includes one or more surfaces 118 on the outer periphery 120 of the rotor assembly 100. The one or more surfaces 118 include a first predetermined shape.

[0041] In addition, the system 101 includes a magnetization unit 122. The magnetization unit 122 includes one or more magnetization surfaces 124 and one or more magnetization windings 126. The one or more magnetization surfaces 124 are configured to magnetize one or more rare earth metals 110 of the rotor assembly 100 by delivering a predetermined power supply using the one or more magnetization windings 126. In one embodiment, the predetermined power supply may vary according to the type of one or more rare earth materials. In another embodiment, the type of one or more rare earth materials may vary according to the application.

[0042] A predetermined power supply can vary according to requirements. In one embodiment, the magnetization unit 122 is configured to control the predetermined power supply using one or more sensing devices. One or more magnetization surfaces 124 of the magnetization unit 122 include a second predetermined shape. The first predetermined shape and the second predetermined shape are constructed in a way that they are positioned relative to each other to avoid misalignment between the rotor assembly 100 and the magnetization unit 122.

[0043] One or more surfaces 118 of the rotor assembly 100 are positioned at a predetermined distance from one or more magnetization surfaces 124 of the magnetization unit 122. In one embodiment, the predetermined distance can vary based on the outer circumference 120 of the rotor assembly 100, the positioning of the first predetermined shape of one or more surfaces 118 and the second predetermined shape of one or more magnetization surfaces 124, and the orientation of one or more rare earth metals 110.

[0044] One or more magnetization windings 126 include different polarities. In one embodiment, the different polarities of one or more magnetization windings 126 include a positive polarity and a negative polarity. One or more magnetization windings 126 having different polarities are configured to magnetize one or more rare earth metals 110 in a manner such that the adjacent magnetic poles of the rotor assembly are opposite (N-S, S-N).

[0045] In addition, the magnetization unit 122 includes one or more flux concentrators 128. One or more flux concentrators 128 are configured to separate one or more magnetization surfaces 124 of the north pole (N) and one or more magnetization surfaces 124 of the south pole (S). One or more magnetization surfaces 124 of the rotor assembly 100, one or more flux concentrators 128, and one or more magnetization surfaces 124 of the magnetization unit 122 are configured to converge magnetic flux lines from the magnetization unit 122 onto one or more rare earth metals 110 positioned in one or more slots 102 of the rotor assembly 100. In one embodiment, one or more flux concentrators 128 are composed of one or more non-magnetic materials. In one embodiment, one or more non-magnetic materials can include, but are not limited to, wood, plastic, copper, paper, aluminum, rubber, and stone. In one embodiment, one or more flux concentrators 128 can be air.

[0046] One or more rare earth metals 110 are bonded to one or more laminated blocks 116 using glue. In one embodiment, one or more rare earth metals 110 are clamped to one or more laminated blocks 116 using one or more clamps. In one embodiment, glue is applied to one or more rare earth metals 110 and then inserted into one or more slots 102. With the help of one or more balance rings 106, one or more laminated blocks 116 are joined together using one or more joining processes. In one embodiment, one or more joining processes can include, but are not limited to, a riveting process, a welding process, a clamping process, an interlocking process, an adhesive process, and a fastening process.

[0047] The rotor shaft is positioned in the shaft slot 108. In one embodiment, one or more assembly techniques are used to position the rotor shaft into the shaft slot 108. In one embodiment, one or more assembly techniques can include, but are not limited to, a press-fitting process. As used herein, a press-fitting process is an assembly where one component is tightly inserted into the hole of another component. The inserted component is typically larger than the mating hole. The assembly is held in place by friction and the force of the two components pushing against each other.

[0048] Furthermore, the rotor assembly 100 is positioned in the magnetization unit 122 to magnetize one or more rare earth metals 110. The magnetization unit 122 also includes a cooling unit 130 and an isolation unit 132. The cooling unit 130 is configured to dissipate the thermal energy generated at one or more magnetization windings 126 while delivering a predetermined power supply to one or more rare earth metals 110. The isolation unit 132 is configured to prevent the magnetic flux (generated during magnetization) from scattering outside the magnetization unit 122. In one embodiment, one or more magnetization windings 126 with different polarities are configured to magnetize one or more rare earth metals one at a time in a manner opposite to one or more adjacent magnetic poles of the rotor assembly (100) (N-S, S-N). The rotor assembly 100 with one or more magnetized rare earth metals 110 is assembled with the stator to form an electric motor.

[0049] Figure 1B A top view of a rotor assembly 100 with a magnetization unit 122 according to an embodiment herein is shown. The magnetization unit 122 includes one or more magnetization surfaces 124 and one or more magnetization windings 126. One or more magnetization surfaces 124 are configured to magnetize one or more rare earth metals 110 of the rotor assembly 100 by delivering a predetermined power supply using one or more magnetization windings 126. In one embodiment, the predetermined power supply can vary according to the type of one or more rare earth materials. In another embodiment, the type of one or more rare earth materials can vary according to the application.

[0050] A predetermined power supply can vary according to requirements. In one embodiment, the magnetization unit 122 is configured to control the predetermined power supply using one or more sensing devices. The rotor assembly 100 includes one or more surfaces 118 on the outer periphery 120 of the rotor assembly 100. The one or more surfaces 118 include a first predetermined shape.

[0051] One or more magnetization surfaces 124 of the magnetization unit 122 include a second predetermined shape. The first predetermined shape and the second predetermined shape are constructed in a manner of positioning relative to each other to avoid misalignment between the rotor assembly 100 and the magnetization unit 122.

[0052] One or more surfaces 118 of the rotor assembly 100 are positioned at a predetermined distance from one or more magnetization surfaces 124 of the magnetization unit 122. In one embodiment, the predetermined distance can vary based on the outer periphery 120 of the rotor assembly 100, the positioning of the first predetermined shape of the one or more surfaces 118 and the second predetermined shape of the one or more magnetization surfaces 124, and the orientation of one or more rare earth metals 110.

[0053] One or more magnetization windings 126 include different polarities. In one embodiment, the different polarities of the one or more magnetization windings 126 include a positive polarity and a negative polarity. The one or more magnetization windings 126 having different polarities are configured to magnetize one or more rare earth metals 110 in such a way that one or more adjacent magnetic poles of the rotor assembly are opposite (N-S, S-N).

[0054] In addition, the magnetization unit 122 includes one or more flux concentrators 128. The one or more flux concentrators 128 are configured to separate one or more magnetization surfaces 124 of the north pole (N) and one or more magnetization surfaces 124 of the south pole (S). The one or more magnetization surfaces 124 of the rotor assembly 100, the one or more flux concentrators 128, and the one or more magnetization surfaces 124 of the magnetization unit 122 are configured to converge magnetic flux lines from the magnetization unit 122 onto one or more rare earth metals 110 positioned in one or more slots 102 of the rotor assembly 100. In one embodiment, the one or more flux concentrators 128 are composed of one or more non-magnetic substances. In one embodiment, the one or more non-magnetic substances can include, but are not limited to, wood, plastic, copper, paper, aluminum, rubber, and stone. In one embodiment, the one or more flux concentrators 128 can be air. The rotor assembly 100 is positioned in the magnetization unit 122 to magnetize one or more rare earth metals 110.

[0055] Figure 1CFIG. 0 shows a partial schematic cross-sectional view of a rotor assembly 100 having a magnetization unit 122 according to an embodiment herein. The magnetization unit 122 includes one or more magnetization surfaces 124 and one or more magnetization windings 126. The one or more magnetization surfaces 124 are configured to magnetize one or more rare earth metals 110 of the rotor assembly 100 by delivering a predetermined power supply using the one or more magnetization windings 126. In one embodiment, the predetermined power supply may vary according to the type of one or more rare earth materials. In another embodiment, the type of one or more rare earth materials may vary according to the application.

[0056] The predetermined power supply may vary according to requirements. In one embodiment, the magnetization unit 122 is configured to control the predetermined power supply using one or more sensing devices. One or more magnetization surfaces 124 of the magnetization unit 122 include a second predetermined shape. The first predetermined shape and the second predetermined shape are constructed in a manner that positions them relative to each other to avoid misalignment between the rotor assembly 100 and the magnetization unit 122.

[0057] One or more surfaces 118 of the rotor assembly 100 are positioned at a predetermined distance from one or more magnetization surfaces 124 of the magnetization unit 122. In one embodiment, the predetermined distance may vary based on the outer circumference 120 of the rotor assembly 100, the positioning of the first predetermined shape of the one or more surfaces 118 and the second predetermined shape of the one or more magnetization surfaces 124, and the orientation of the one or more rare earth metals 110.

[0058] In addition, the magnetization unit 122 includes one or more flux concentrators 128. The one or more flux concentrators 128 are configured to separate the one or more magnetization surfaces 124 of the north pole (N) and the one or more magnetization surfaces 124 of the south pole (S). The one or more magnetization surfaces 124 of the rotor assembly 100, the one or more flux concentrators 128, and the one or more magnetization surfaces 124 of the magnetization unit 122 are configured to converge magnetic flux lines from the magnetization unit 122 onto the one or more rare earth metals 110 positioned in one or more slots 102 of the rotor assembly 100. In one embodiment, the one or more flux concentrators 128 are composed of one or more non-magnetic materials. In one embodiment, the one or more non-magnetic materials may include, but are not limited to, wood, plastic, copper, paper, aluminum, rubber, and stone. In one embodiment, the one or more flux concentrators 128 may be air.

[0059] Figure 2AShows a top view of one or more laminates 114 of a rotor assembly 100 according to an embodiment herein. The system 101 includes one or more laminates 114. One or more laminates 114 are stacked together to construct a laminate block 116. One or more laminate blocks 116 are stacked together to construct the rotor assembly 100.

[0060] Figure 2B Shows an isometric view of a laminate block 116 of a rotor assembly 100 according to an embodiment herein. The laminate block 116 of the rotor assembly 100 includes one or more slots 102. One or more slots 102 are mechanically configured to provide a predetermined space for positioning one or more rare earth metals in a non-magnetized state. One or more rare earth metals 110 are magnetized using a magnetization unit 122. The adjacent magnetic poles of the north pole (N) will be the south pole (S).

[0061] Figure 2C Shows an isometric view of one or more laminate blocks 116 of a rotor assembly 100 according to an embodiment herein. One or more laminate blocks 116 are stacked together to construct the rotor assembly 100. One or more laminate blocks 116 are arranged and magnetized in such a way that the same magnetic poles (N-N, S-S) will be positioned together on the longitudinal axis. With the help of one or more joining processes, one or more balance rings 106 are configured to arrange one or more laminate blocks 116 together. In one embodiment, one or more joining processes may include, but are not limited to, a riveting process, a welding process, a clamping process, an interlocking process, an adhesive process, and a fastening process.

[0062] With the help of glue, one or more magnets are longitudinally positioned as the same magnetic poles (N-N, S-S) in a plurality of magnetic slots. In one embodiment, one or more clamps are used to clamp one or more rare earth metals 110 to one or more laminate blocks 116.

[0063] Figure 3 Shows an exploded view of a motor 300 of the system 101 according to an embodiment herein. Figure 3 The motor 300 shows a rotor assembly 100 having a stator 304. The rotor shaft 302 of the rotor assembly is positioned in the shaft slot 108. In one embodiment, the rotor shaft 302 of the rotor assembly 100 is positioned in the shaft slot 108 using a press-fit process. The press-fit process used herein is an assembly in which one component is tightly inserted into the hole of another component. The inserted component is typically larger than the mating hole. The assembly is held in place by friction and the force of the two components pushing against each other. In addition, Figure 3 It is clearly shown that the rotor assembly 100 with one or more magnetized rare earth metals is placed / assembled into the stator 304 to form a motor.

[0064] Figure 4A and4B A method 400 for magnetizing one or more rare earth metals 110 to construct the rotor assembly 100 of FIG. 1 in accordance with an embodiment of the present disclosure is shown. At step 402, one or more laminates are stacked together to construct a laminated block 116. Each of the one or more laminates 114 includes one or more connecting means. The one or more connecting means are configured to stack the one or more laminates 114 together.

[0065] At step 404, one or more rare earth metals 110 are positioned into one or more slots 102. At step 406, one or more rare earth metals 110 are bonded into one or more slots 102. In one embodiment, glue is applied to the one or more rare earth metals 110 and then inserted into the one or more slots 102. In one embodiment, one or more clamps are used to clamp the one or more rare earth metals 110 to the one or more laminated blocks 116.

[0066] At step 408, in the presence of the rotor shaft 302, one or more laminated blocks 116 are stacked using one or more joining processes to construct a rotor assembly 100 having one or more balance rings 106. The rotor assembly 100 includes one or more surfaces 118 on the outer periphery 120 of the rotor assembly 100. The one or more surfaces 118 of the rotor assembly 100 include a first predetermined shape. In one embodiment, the one or more joining processes may include, but are not limited to, a riveting process, a welding process, a clamping process, an interlocking process, a bonding process, and a fastening process.

[0067] At step 410, the rotor assembly is balanced. With the help of one or more joining processes, the one or more balance rings 106 are configured to arrange the one or more laminated blocks 116 together. In one embodiment, the one or more joining processes may include, but are not limited to, a riveting process, a welding process, a clamping process, an interlocking process, a bonding process, and a fastening process. At step 412, the rotor assembly 100 is set into a magnetization unit 122. The magnetization unit 122 includes one or more magnetization surfaces 124 and one or more magnetization windings 126. The one or more magnetization surfaces 124 of the magnetization unit 122 include a second predetermined shape. At step 414, the first predetermined shape and the second predetermined shape are correspondingly positioned together in a manner that avoids misalignment of the rotor assembly 100 with the magnetization unit 122.

[0068] In step 416, one or more surfaces 118 of the rotor assembly 100 are positioned at a predetermined distance from one or more magnetization surfaces 124 of the magnetization unit 122. In one embodiment, the predetermined distance varies based on the outer circumference of the rotor assembly 100, the positioning of a first predetermined shape of one or more surfaces 118 and a second predetermined shape of one or more magnetization surfaces 124, and the orientation of one or more rare earth metals 110. In another embodiment, the magnetization unit 122 further includes one or more flux concentrators 128.

[0069] In step 418, one or more surfaces 118 of the rotor assembly 100, one or more flux concentrators 128, and one or more magnetization surfaces 124 of the magnetization unit 122 are used to converge magnetic flux lines from the magnetization unit 122 onto one or more rare earth metals 110. In one embodiment, one or more magnetization windings 126 include different polarities. In step 420, one or more rare earth metals 110 are magnetized using one or more magnetization windings 126 by delivering a predetermined power supply. One or more magnetization windings 126 include different polarities. The different polarities include a positive polarity and a negative polarity. The method 400 further includes magnetizing one or more rare earth metals 110 in a manner such that one or more adjacent magnetic poles of the rotor assembly 100 are opposite (N-S, S-N) using one or more magnetization windings 126 having different polarities.

[0070] The method 400 further includes using one or more flux concentrators 128 to separate one or more magnetization surfaces 124 of the north pole (N) and one or more magnetization surfaces 124 of the south pole (S). The method 400 further includes using the magnetization unit 122 to uniformly magnetize one or more rare earth metals 110 of the rotor assembly 100 all at once in a manner such that one or more adjacent magnetic poles of the rotor assembly (100) are opposite (N-S, S-N).

[0071] The proposed system does not require skilled professionals to insert magnets to ensure alternate poles. The proposed system does not require additional mechanisms to check for alternate poles. The proposed system eliminates the misalignment of magnets with incorrect polarities that can cause defects in the rotor assembly 100 and potentially lead to the rejection of the rotor assembly 200 and the cost of internal process defects. Additionally, the proposed system makes the packaging, storage, and transportation of the various rare earth materials 110 easier when compared to magnetized magnets. The proposed system provides for easy handling from the motor assembly line to the magnetization station. The lack of wear or less wear of the coating material on the magnets results in greater corrosion and abrasion resistance. Since non-magnetized magnets are easy to handle, the proposed system reduces the overall assembly time. One or more balance rings 106, one or more bonding processes, the rotor shaft, and the balancing station of the proposed system are simpler. Due to one or more rare earth metals 110, the application of glue is easier and more uniform because there is no attraction between the core and the magnet. Due to one or more rare earth metals 110, the repulsive force acting between evenly distributed stacks is minimal, which aids in one or more bonding processes. Additionally, no gaps or minimal gaps are formed between the evenly distributed stacks. The proposed system ensures and improves the safety of the operator during the handling of the material of one or more rare earth metals 110 when compared to magnetized magnets.

[0072] The proposed system provides a solution to the problem of demagnetization due to the heat generated by the rotation of the motor through a repeated magnetization process. Additionally, by inserting one or more rare earth metals in a non-magnetized state into one or more slots of the rotor assembly, the proposed system provides a solution to the problem that occurs when positioning the same poles (N-N or S-S) of the magnets together along the longitudinal axis of the rotor assembly. Besides this, the proposed system ensures equal Tesla values of one or more magnetized rare earth metals through single magnetization to avoid polarization imbalance, wear problems, voltage harmonics, and inefficiencies. Additionally, the proposed system controls the vibration problem by avoiding torque variations in the rotor assembly. The torque variation is reduced through single magnetization.

[0073] Besides this, the proposed system reduces the voltage harmonics of the motor by providing one or more surfaces 118 on the outer periphery 120 of the rotor assembly 100 instead of on a circular rotor. A predetermined power supply is provided to each of the one or more rare earth materials 110 using one or more magnetization windings 126 of the magnetization unit 122. The one or more magnetization windings 126 include different polarities to magnetize adjacent poles of the rotor assembly (100) in opposite directions (N-S, S-N). The proposed system reduces the eddy current losses in the motor by constructing the rotor assembly as multiple components.

[0074] In addition, the proposed system provides a method for magnetizing one or more rare earth metals 110 with an effective Tesla value. The Tesla value of the magnetized one or more rare earth metals 110 can vary according to the type of the one or more rare earth metals 110 and the predetermined power supply of one or more magnetization windings 126 of the magnetization unit 122.

[0075] The above description of the specific embodiments will fully disclose the general nature of the embodiments herein, such that others can, by applying current knowledge, readily modify and / or adapt these specific embodiments for various applications without departing from the general concept. Therefore, these adaptations and modifications should and are intended to be understood within the meaning and equivalence scope of the disclosed embodiments. It should be understood that the wording or terminology used herein is for the purpose of description and not limitation. Thus, while the embodiments herein are described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the appended claims. Improvements and modifications can be incorporated herein without departing from the scope of the present invention.

[0076] List of Reference Numerals

[0077] System - 101

[0078] Rotor assembly - 100

[0079] One or more slots - 102

[0080] One or more weight relief cuts - 104

[0081] One or more balance rings - 106

[0082] Shaft slot - 108

[0083] One or more rare earth metals - 110

[0084] One or more laminates - 114

[0085] Laminated block or one or more laminated blocks - 116

[0086] One or more surfaces - 118

[0087] Periphery - 120

[0088] Magnetization unit - 122

[0089] One or more magnetization surfaces - 124

[0090] One or more magnetization windings - 126

[0091] One or more flux concentrators - 128

[0092] Cooling unit - 130

[0093] Isolation unit - 132

[0094] Rotating shaft - 302

[0095] Stator - 304.

Claims

1. A system (101) for magnetizing one or more rare earth metals (110) to construct a rotor assembly (100), comprising: One or more laminates (114) stacked together to construct a laminated block (116); One or more laminated blocks (116) stacked together to construct the rotor assembly (100), wherein the rotor assembly (110) includes one or more surfaces (118) on an outer periphery (120) of the rotor assembly (100); The rotor assembly (100) includes one or more slots (102) mechanically configured to provide a predetermined space for positioning one or more rare earth metals (110) in a non-magnetized state; And A magnetization unit (122) including one or more magnetization surfaces (124) and one or more magnetization windings (126), wherein the one or more magnetization surfaces (124) are configured to magnetize the one or more rare earth metals (110) of the rotor assembly (100) by delivering a predetermined power supply using the one or more magnetization windings (126).

2. The system according to claim 1, wherein The one or more magnetization windings (126) include different polarities, wherein the one or more magnetization windings (126) having different polarities are configured to magnetize the one or more rare earth metals (110) in a manner such that one or more adjacent magnetic poles of the rotor assembly (100) are opposite (N-S, S-N).

3. The system according to claim 1, wherein The one or more surfaces (118) of the rotor assembly (100) include a first predetermined shape, wherein the one or more magnetization surfaces (124) of the magnetization unit (122) include a second predetermined shape.

4. The system according to claim 3, wherein, The first predetermined shape and the second predetermined shape are constructed in a manner of being positioned relative to each other to avoid misalignment between the rotor assembly (100) and the magnetization unit (122).

5. The system according to claim 1, wherein, The one or more surfaces (118) of the rotor assembly (100) are positioned at a predetermined distance from the one or more magnetization surfaces (124) of the magnetization unit (122).

6. The system according to claim 5, wherein The predetermined distance varies based on the outer periphery (120) of the rotor assembly (100), the positioning of the first predetermined shape of the one or more surfaces (118) and the second predetermined shape of the one or more magnetization surfaces (124), and the orientation of the one or more rare earth metals (110).

7. The system according to claim 1, wherein The magnetization unit (122) further includes one or more flux concentrators (128), wherein the one or more flux concentrators (128) are configured to separate the one or more magnetized surfaces (124) of the north pole (N) and the one or more magnetized surfaces (124) of the south pole (S), wherein one or more surfaces (118) of the rotor assembly (100), the one or more flux concentrators (128), and the one or more magnetized surfaces (124) of the magnetization unit (122) are configured to converge magnetic flux lines from the magnetization unit (122) onto the one or more rare earth metals (110) located on the one or more slots of the rotor assembly (100).

8. The system according to claim 1, wherein, The magnetization unit (122) is configured to uniformly magnetize the one or more rare earth metals (110) of the rotor assembly (100) all at once in such a way that one or more adjacent magnetic poles of the rotor assembly (100) are opposite (N-S, S-N).

9. A method (400) of magnetizing one or more rare earth metals (110) to construct a rotor assembly (100), comprising: Stacking one or more laminates (114) together to construct a laminated block (116); Positioning the one or more rare earth metals into one or more slots (102); Adhering the one or more rare earth metals to the one or more slots (102); In the presence of the rotor shaft (302), stacking one or more laminated blocks (116) using one or more joining processes to construct a rotor assembly (100) having one or more balance rings; Balancing the rotor assembly (100), wherein the rotor assembly (100) includes one or more surfaces (118) on the outer periphery (120), wherein the one or more surfaces (118) of the rotor assembly (100) include a first predetermined shape; Placing the rotor assembly (100) into the magnetization unit (122), wherein the magnetization unit (122) includes one or more magnetized surfaces (124) and one or more magnetization windings (126), wherein the one or more magnetized surfaces (124) of the magnetization unit (122) include a second predetermined shape; Accordingly positioning the first predetermined shape and the second predetermined shape together in a manner that avoids misalignment of the rotor assembly (100) with the magnetization unit (122); Positioning the one or more surfaces (118) of the rotor assembly (100) at a predetermined distance from the one or more magnetized surfaces (124) of the magnetization unit (122), wherein the predetermined distance varies based on the outer periphery (120) of the rotor assembly (100), the positioning of the first predetermined shape of the one or more surfaces (118), the positioning of the second predetermined shape of the one or more magnetized surfaces (124), and the orientation of the one or more rare earth metals (110). Using the one or more surfaces (118) of the rotor assembly (100), one or more flux concentrators (128), and the one or more magnetization surfaces (124) of the magnetization unit (122) to converge magnetic flux lines from the magnetization unit (122) onto the one or more rare earth metals (110), wherein the magnetization unit (122) further includes the one or more flux concentrators (128); and Magnetizing the one or more rare earth metals (110) by passing a predetermined power supply through the one or more magnetization windings (126), wherein the one or more magnetization windings (126) include different polarities.

10. The method (400) according to claim 10, wherein, The method (400) further includes: using the one or more magnetization windings (126) having different polarities to magnetize the one or more rare earth metals (110) in a manner such that one or more adjacent magnetic poles of the rotor assembly (100) are opposite (N-S, S-N).

11. The method (400) according to claim 10, wherein, The method (400) further includes: using the one or more flux concentrators (128) to separate the one or more magnetization surfaces (124) of the north pole (N) and the one or more magnetization surfaces (124) of the south pole (S).

12. The method (400) according to claim 10, wherein, The method (400) further includes: using the magnetization unit (122) to uniformly magnetize the one or more rare earth metals (110) of the rotor assembly (100) all at once in a manner such that one or more adjacent magnetic poles of the rotor assembly (100) are opposite (N-S, S-N).

13. The method (400) according to claim 10, wherein, The one or more joining processes include a riveting process, a welding process, a clamping process, an interlocking process, an adhesive process, and a fastening process.

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