Method and apparatus for placing magnet segments of an axial flux motor

Abstract

According to one disclosed method, a magnet segment can be linearly slid along a first surface and onto a second surface of a back iron of a rotor, where the first surface is disposed at or above a ledge extending upward from the second surface at an outer edge of the back iron to enable the magnet segment to slide over the ledge before the magnet segment is slid onto the second surface. According to another disclosed method, a first end of a magnet segment can be pressed against a resilient member positioned at an inner portion of a back iron of a rotor such that a force applied by the resilient member pushes a second end of the magnet segment against a ledge positioned at an outer portion of the back iron.

Description

[0001] Cross-citation of related applications

[0002] This application claims the right to U.S. Provisional Application No. 63 / 448,212, filed February 24, 2023, entitled SEGMENTED MAGNET PLACING APPARATUS FOR AXIALFLUX MOTORS, subject to 35 U.S.SC §119(e), the entire contents of which are hereby incorporated by reference for all purposes. Background Technology

[0003] Axial flux motors and generators, described by several patents (including Nos. 7,109,625; 10,170,953; 9,859,763; 10,211,694; and 10,256,690, the entire contents of which are incorporated herein by reference), are characterized by a generally planar printed circuit board stator assembly inserted between magnets having alternating north and south magnetic poles. These magnets can be attached to the shaft via a “back iron” for connection to a mechanical load (or a generator power source). The back iron also serves as a flux return path for the magnets, thereby providing a high permeability connection between adjacent magnetic poles. Summary of the Invention

[0004] According to one example embodiment of this disclosure, a method involves linearly sliding a magnet segment along a first surface and onto a second surface of a back iron of a rotor, wherein the first surface is located at or above a flange extending upward from the second surface at the outer edge of the back iron, such that the magnet segment can slide over the flange before sliding onto the second surface.

[0005] According to another embodiment of this disclosure, a method involves pressing a first end of a magnet segment against an elastic member located at an inner portion of a back iron of a rotor, such that a force applied by the elastic member pushes a second end of the magnet segment against a flange located at an outer portion of the back iron. Attached Figure Description

[0006] Figure 1 The assembly showcases a conventional rotor structure that includes a ring magnet and a corresponding back iron.

[0007] Figure 2 The assembly includes a conventional rotor structure with back iron having individual recesses for the respective magnet segments;

[0008] Figure 3Examples of jigs according to some embodiments of the present disclosure are shown that can be used to facilitate the placement of magnet segments onto a back iron to produce a rotor structure;

[0009] Figure 4 This demonstrates some embodiments that can be combined according to the present disclosure. Figure 3 The example of a jig used in the illustration is a back iron;

[0010] Figure 5 This explains how, according to some embodiments of the present disclosure, [the following can be done / implemented]. Figure 3 The jig shown in the image is attached to Figure 4 The back iron shown in the article;

[0011] Figure 6 yes Figure 5 The sectional view of the assembly shown in the image;

[0012] Figure 7 According to some embodiments of this disclosure, it can be used to place magnet segments onto... Figure 5 and 6 A perspective view of an example magnet placement device in the assembly shown in the image;

[0013] Figure 8 yes Figure 7 The cross-sectional side view of the example magnet placement device shown in the image;

[0014] Figure 9A , 9B 9C is an embodiment of the present disclosure. Figure 7 and 8 The cross-sectional view shown is of a portion of an example magnet placement device, illustrating the process of placing a magnet segment onto... Figure 5 and 6 The steps in the process of the example assembly on the back iron shown in the figure;

[0015] Figure 10 Compared to some embodiments of this disclosure Figure 7 and 8 The magnet placement device shown includes perspective views of several possible enhanced examples of magnet placement devices;

[0016] Figure 11 Perspective views showing example rotor assemblies manufactured using the techniques disclosed herein, according to some embodiments of this disclosure; and

[0017] Figure 12 exhibit Figure 11 The example rotor assembly shown is a cross-sectional side view. Detailed Implementation

[0018] Some previous axial flux motor / generator designs have used toroidal magnets that require a very simple back iron to function. Figure 1 An example of this toroidal magnet 102 and its corresponding back iron 104 is shown. As shown, the back iron 104 for the toroidal magnet 102 may be contained in a simple disk-shaped structure 106 having a flange 108 at its outer diameter. Other previous designs have used segmented magnets instead of toroidal magnets. Some of these designs have employed back irons with recesses for holding individual magnet segments. Figure 2 Examples of back irons 202 with individual recesses 204 for corresponding magnet segments 206 are shown. However, the configuration of these types of back irons 202 is often quite complex, making them difficult and expensive to manufacture. Furthermore, the need to place individual magnet segments 206 onto back irons 202 presents additional challenges compared to toroidal magnets (example techniques for placing toroidal magnets onto back irons are disclosed in Adhesive No. 9,673,688, the entire contents of which are incorporated herein by reference), because each magnet segment 206 must be individually positioned and a large number of individual components must be placed.

[0019] Nevertheless, at least for certain applications, it is still desirable to use magnet segment 206 instead of toroidal magnet 102, because toroidal magnet 102 (e.g. Figure 1 (as shown in the image) compared to magnet segment 206 (e.g.) Figure 2 (As shown in the figure) It has some significant drawbacks. For example, the toroidal magnet 102 requires a custom magnetization fixture, can only achieve a specific diameter, and produces magnetic poles that are not as consistent as those of the magnet segment 206.

[0020] According to some embodiments of this disclosure, fixture 302 can be used. Figure 3 (as shown in the image) and the flange 402 integrated with the back iron 404 of the rotor. Figure 4 (as shown in the diagram) to position the magnet segment 206. The flange 402 can be configured and arranged to address the centripetal force applied to the individual magnet segments 206, resulting in the rotor assembly 1100 (…). Figure 11 and 12 (As shown in the diagram) Angular constraint can be achieved solely with adhesive. This disclosure also provides a method for assembling a magnet segment 206 onto a back iron 404 using a jig 302, a method that can be easily automated for mass production. In some embodiments, the jig 302 can be removed from the back iron 404 after it has been used to arrange the magnet segment 206 onto the back iron 404. In other embodiments, the jig 302 can be left in its proper position on the back iron 404 and included as an assembly of the completed rotor assembly. In some embodiments, a magnetization step can be added during assembly, allowing the use of unmagnetized magnets that are easier to handle and ship from the manufacturer.

[0021] This disclosure also introduces an apparatus for placing individual magnet segments 206 onto a back iron 404 to produce a rotor assembly 1100, the apparatus allowing the use of a back iron 404 that is much easier to manufacture, while maintaining accurate placement of the magnet segments 206 and addressing the centripetal force on the magnet segments 206 as the rotor assembly 1100 rotates.

[0022] Previous designs have used a toroidal magnet 102, which is magnetized using a magnetizing jig to have alternating axial poles required to generate an alternating axial magnetic field through a stator used to generate torque in an electric motor or to respond to torque in a generator. The production of the toroidal magnet 102 is complex and results in waste of rare-earth material between the poles and in the central hole. The toroidal magnet 102 can also exhibit significant magnetic field strength variation due to its size, as it must be cut from a large ingot and it is difficult to consistently align the magnetic domains of the magnetic particles across large blocks, leading to greater variability in magnetic field strength. Furthermore, due to the necessary size of the magnetic material to be processed, the single-piece toroidal magnet 102 is typically limited to a diameter of less than six inches. A segmented magnet, where each section forms a single pole, produces less waste, eliminates the need for custom magnetizing jigs, produces more consistent poles, and can be used in larger diameter designs.

[0023] Placing the magnet segments 206 onto the back iron presents additional challenges compared to the toroidal magnet 102. During assembly, if the magnet segments 206 are not constrained angularly or radially, their attractive forces will cause them to move. If an adhesive is used between the back iron and the magnet segments 206, the adhesive may act as a lubricant before curing, potentially exacerbating the movement problem.

[0024] A solution ( Figure 2 (As described above) uses a back iron 202 with individual recesses 204 for the magnet segment 206. The back iron 202 is complex and expensive to manufacture. Each recess 204 must be maintained to tight tolerances to prevent movement of the magnet segment 206, and the small corner radius of the recess requires the use of small tools. In contrast, the back iron 104 for the toroidal magnet 102 ( Figure 1 (As described in the text) It only has large concentric circular features and can be machined on a mill or lathe using large tools.

[0025] The novel jig 302 disclosed in this article Figure 3 (As shown in the diagram) This advantageously facilitates the placement of the magnet segment 206 onto a back iron 404 of the type conventionally used for toroidal magnets 102, thus realizing the benefits of using the magnet segment 206 while maintaining the manufacturability of the back iron 404. (See the following in conjunction with...) Figure 5 and 6 Description, for example, Figure 3 The jig 302 shown can be attached to Figure 4 The back iron 404 shown in the figure is used to form assembly 500.

[0026] like Figure 3 As shown, jig 302 may have spacers 304 for angularly positioning the magnet segment 206. Spacers 304 may be attached to an annular region 308 of jig 302. Furthermore, as described in more detail below, jig 302 may also have a mechanism for pushing the magnet segment 206 against a flange 402 positioned at the outer diameter of back iron 404 for radial positioning. In some embodiments, this mechanism may include a resilient member, such as a resilient O-ring 306 or spring, arranged to be positioned at an inner portion of back iron 404 when jig 302 is attached to back iron 404, compressing when the magnet segment 206 is inserted. An annular space 310 may be provided between spacers 304 and an inner flange 312 of jig 302 to facilitate placement of the resilient member (e.g., O-ring 306) around the inner flange 312. In some embodiments, the flange 402 located at the outer diameter of the back iron 404 can be integral with the back iron 404, for example in Figures 4 to 6 The embodiment shown herein. In other embodiments, flange 402 may alternatively be a component of jig 302. As used herein, when two components are formed or attached in a manner that prevents them from being separated without damaging at least one of the components, one component is "integrated" with the other.

[0027] Before the magnet segment 206 is introduced onto the back iron 404, an adhesive may be placed between the magnet segment 206 and the back iron 404. When the magnet segment 206 is inserted into the recess 204 and one end of the magnet segment 206 is pressed against the elastic member, the elastic force generated by the elastic member can push the other end of the magnet segment against the flange 402. Therefore, the elastic member can apply a radial force to the magnet segment 206, thereby pushing it against the flange 402 until the adhesive has at least partially cured.

[0028] In some implementations, the rotor assembly 1100 produced using fixture 302 ( Figure 11 and 12 During operation (as shown in the diagram), the centripetal force can be resolved by the flange 402, preventing the adhesive from being stressed by the force. The back iron 404, typically made of steel, can be easily manufactured, for example, by turning on a lathe, to produce simple concentric features, such as a center hole 406 with an accurate diameter and, in some embodiments, the flange 402.

[0029] In some embodiments, jig 302 may be removable and reusable, with minimal requirements for strength and no requirements for magnetic properties. In other embodiments, jig 302 may remain in place on back iron 404 after it has been used to position the magnet segment 206 on back iron 404, and thus may be included as an assembly of the completed rotor assembly. In either case, jig 302 may be made of a variety of materials (e.g., plastic and / or aluminum). It may be manufactured in different ways, including but not limited to computer numerical control (CNC) machining or three-dimensional (3D) printing. It may have complex geometries that may be difficult to manufacture, but in at least some cases, it can be used to construct a number of rotor assemblies 1100 because it only needs to be held in place until the adhesive between the magnet segment 206 and back iron 404 has at least partially cured.

[0030] An example process for using jig 302 will now be described. As an initial step, jig 302 can be correctly positioned on and attached to back iron 404. This can be done, for example, by using screw 502 ( Figure 5 and 6 As shown in the diagram, positioning and attachment fixture 302 are used to form assembly 500. Figure 3 and 4 As shown, in some embodiments, jig 302 may include holes 314 that can be aligned with corresponding holes 408 drilled or otherwise formed in the back iron 404, and screw 502 may be screwed into or otherwise secured in the aligned holes 314, 408. In embodiments where jig 302 is held in place on the back iron 404 after being used to position the magnet segment 206, a lower profile screw 502 and / or recessed holes 314 may be used to keep the upper surface of the resulting rotor assembly relatively flat.

[0031] In some embodiments, additionally or alternatively, jig 302 may include a circular protrusion (not shown) that can be used to position jig 302 on back iron 404 by engaging the circular protrusion with a center hole 406 of back iron 404. The circular protrusion is generally a precision feature and can then be secured to jig 302 with a screw 502. Additionally or alternatively, in some embodiments, other mechanisms for securing jig 302 to back iron 404 may be employed, which can be implemented more quickly in mass production. For example... Figure 5 As shown, when the jig 302 is attached to the back iron 404, several pairs of spacers 304 can form recesses 504 adapted to receive the corresponding magnet segments 206.

[0032] When fixture 302 is attached to back iron 404 (e.g.) Figure 5 and 6In the case shown, an adhesive (e.g., Loctite AA331) can be applied to the area of ​​the back iron 404 within the recess 504. Some adhesives may require an activator (e.g., Loctite SF7387) to be applied to the back iron 404 prior to the adhesive. The magnet segment 206 can be angularly constrained using this adhesive after the jig 302 is removed. It is desirable to use a fast-curing adhesive to minimize the amount of time required to position the jig 302 properly on the back iron 404 after the magnet segment 206 is placed.

[0033] After applying the adhesive, the magnet segment 206 can be placed into one of the recesses 504 and pressed radially inward against the elastic member (e.g., O-ring 306) of the jig 302 until the outer edge of the magnet segment 206 slides over the flange 402 and the bottom portion of the magnet segment 206 becomes flush with the upper surface 602 of the back iron 404. Figure 6 As explained in the description. In its uncured state, the adhesive may act as a lubricant, thus allowing the elastic force generated by the elastic components of jig 302 (e.g., O-ring 306) to push the magnet segment 206 against the flange 402 of the back iron 404. This process can be repeated for the number of magnet segments 206 required to complete the rotor assembly 1100. In embodiments where jig 302 is removed from the back iron 404 after being used to position the magnet segments 206, jig 302 can be held in place at least until the adhesive has cured, or partially cured, to the point that jig 302 can be removed without disturbing the magnet segments 206. Then, jig 302 can be removed from the back iron 404 (e.g., by removing screw 502) and used for assembling the subsequent rotor assembly 1100.

[0034] Figure 7 and 8 Perspective and cross-sectional side views of a first example magnet placement apparatus 700, according to some embodiments of the present disclosure, are shown for placing a magnet segment 206 into a recess 504. Figure 8 As best viewed, the magnet placement device 700 may include a pushing member (e.g., a pusher 702) that can slide along a guide rail 716 to separate the magnet segment 206a from the bottom of the stack 704 of magnet segments 206 disposed in a magazine 714, and then push the magnet segment 206a along the upper surface of a slide 708 of the magnet placement device 700 and push it into a recess 504a aligned with the end 706 of the slide 708. The slide 708 may be rigidly attached to the guide rail 716 or integrated with the guide rail 716.

[0035] Magnetized magnets are typically supplied in a stack 704 with spacers 710 to reduce forces between adjacent magnet segments 206. Therefore, in some embodiments, components of the magnet placement device 700 (e.g., spacer ejector 712) can be used to eject spacers 710a as magnet segments 206a move linearly along a slide 708 toward a recess 504a. In the illustrated example, the spacer ejector 712 includes an angled rod that has a gap above the top of the magnet segment 206a but engages the spacer 710a, thereby pushing the spacer 710a away from the magnet segment 206a. This process can be repeated for the number of magnet segments 206 required to complete the rotor assembly 1100.

[0036] for Figure 7 The magnet placement device 700 shown in the diagram allows for the placement of only one polarity of a magnet segment at a time, without requiring the loading of the cassette 714 or the flipping of the stack 704, because all the magnet segments 206 in the stack 704 have their north poles oriented in one direction (e.g., upward) and their south poles oriented in the opposite direction (e.g., downward). Therefore, using this device, both poles can be placed by first placing all the upward-facing south poles, and then flipping the stack 704 of the remaining magnet segments 206 (or loading a new stack 704 of the oppositely oriented magnet segments 206) and placing all the upward-facing south poles, and vice versa. In other embodiments, at least one additional magnet placement device 700 may be employed, for example, positioned to load magnet segments into recesses 504 that are angularly offset from recesses 504 loaded by another magnet placement device 700, one magnet placement device 700 being configured to place the upward-facing north pole and the other magnet placement device 700 being configured to place the upward-facing south pole.

[0037] In some embodiments, the guide rail 716 of the magnet placement device 700 may be constructed from the soft magnetic material (e.g., steel) to which the magnet segment 206 will be attracted, or at least a portion of the guide rail 716 may comprise an elongated soft magnetic component (e.g., a steel rod oriented in the direction of movement of the magnet segment 206). In such embodiments, the magnet segment 206 may be aligned along its longest axis with this soft magnetic feature, which is typically the desired orientation for placing the magnet segment 206 into the recess 504 of the fixture 302. Thus, the guide rail 716 configured in this manner can maintain the magnet segment 206 in proper orientation for placement until it is inserted into the recess 504.

[0038] In some embodiments, the magnet placement device 700 can be operated manually, for example, by aligning the recess 504 of the jig 302 on the back iron 404 with the end 706 of the slide 708 and manually actuating the pusher 702 to push the magnet segment 206 from the stack 704 into the recess 504. In other embodiments, one or more operations of the magnet placement device 700 can be partially or fully automated, as described in more detail below.

[0039] Figure 9A , 9B And 9C is Figure 7 and 8 The cross-sectional view shown is of a portion of the example magnet placement device 700, illustrating the placement of magnet segment 206a to... Figure 5 and 6 The steps in the example process of the back iron 404 of the assembly 500 shown in the figure.

[0040] As by Figure 9A Arrow 902 indicates that the pusher 702 of the magnet placement device 700 can contact the first end 904 of the magnet segment 206a and linearly push the magnet segment 206a along the upper surface 906 of the slide 708 of the magnet placement device 700 and toward the cavity 908 defined by the annular region 308 of the fixture 302, the pair of spacers 304 of the fixture 302, and the upper surface 602 of the back iron 404. As illustrated, the assembly 500 can be arranged relative to the magnet placement device 700 such that the upper surface 906 of the slide 708 is positioned at or above the upper surface 910 of the flange 402 of the back iron 404, thus allowing the magnet segment 206a to slide above the flange 402 and toward the cavity 908. As previously mentioned, in an alternative embodiment, the flange 402 may be a component of the fixture 302 rather than the back iron 404.

[0041] like Figure 9B As shown, after the magnet segment 206a has been pushed (by pusher 702) into the cavity 908, the gravity and / or attraction between the magnet segment 206a and the back iron 404 can cause the second end 912 of the magnet segment 206a to move toward the upper surface 602 of the back iron 404. When the second end 912 of the magnet segment 206a contacts the elastic member (e.g., O-ring 306), the elastic member can deform sufficiently to allow the first end 904 of the magnet segment 206a to move past the inner edge 914 of the flange 402. Figure 9B Arrow 916 indicates that once the first end 904 of the magnet segment 206a has been pushed past the inner edge 914 of the flange 402, the gravity and / or attraction between the magnet segment 206a and the back iron 404 can cause the first end 904 of the magnet segment 206a to move toward the upper surface 602 of the back iron 404.

[0042] like Figure 9C As shown, the first end 904 of the magnet segment 206a can be moved downwards until the bottom portion 918 of the magnet segment 206a becomes flush with the upper surface 602 of the back iron 404. In this configuration, the elasticity of the resilient member (e.g., O-ring 306) can be used to press the first end 904 of the magnet segment 206a against the inner edge 914 of the flange 402. As previously mentioned, in some embodiments, an adhesive can be applied to the upper surface 602 of the back iron 404 and / or the bottom portion 918 of the magnet segment 206a before pushing the magnet segment 206a onto the back iron 404, and in this uncured state, it can act as a lubricant to facilitate the movement of the magnet segment 206a along the upper surface 602 toward the inner edge 914 of the flange 402, due to the elasticity applied by the resilient member (e.g., O-ring 306).

[0043] Figure 10 Compared to Figure 7 and 8 The magnet placement device 700 shown includes several possible enhanced examples of the magnet placement device 1000. For example... Figure 10 As shown, in some embodiments (e.g., for mass production), a rotatable device (e.g., rotary table 1002) can be used to automate the rotation of the back iron 404 to present different recesses 504 to the end 706 of the slide table 708 for placement of the magnet segment 206. Furthermore, as also... Figure 10 As shown in the diagram, in some embodiments, a linear actuator 1004 or a ball screw mechanism may be used to cause linear movement of the pusher 702 along the guide rail 716 to, for example, separate the magnet segment 206a from the stack 704 and then push the magnet segment 206a into the recess 504a / cavity 908 (as described above). Figure 8 and 9A (as described in 9C).

[0044] like Figure 10 Additionally, it is shown that in some embodiments, an adhesive applicator 1006 may be used to automate the application of adhesive to the area of ​​the back iron 404 between the spacers 304 before the magnet segment 206 is placed into the recess 504.

[0045] Finally, and still as Figure 10As described, the magnet placement device 1000 can be further adapted to include a magnetization jig 1008, thereby allowing the use of unmagnetized magnet segments 1010 that are easier to transport and handle. The magnetization jig 1008 may include, for example, a coil 1012 for generating magnetic flux and a yoke 1014 for axially guiding the magnetic flux through the magnet segments 206. As shown, in some embodiments, the magnetization jig 1008 may be positioned between the housing 714 and the jig 302 such that the magnetization of individual magnet segments 206 can be performed as an additional step after the magnet segments 206 are pushed out of the stack 704 and before they slide onto the back iron 404 within the recess 504. In some embodiments, the magnetization jig 1008 may magnetize the individual magnet segments 206 as they slide from the housing 714 into the recess 504. The advantage of using this magnetizing fixture 1008 is that the two poles of the magnet segment 206 can be positioned using the same linear actuation mechanism, wherein control electronics are used to alternate the direction of the current through the coil 1012 to achieve alternating upward-facing north and south magnetic poles. When using the unmagnetized magnet segment 1010, it is not necessary to include spacers between the magnet segments (e.g., Figure 7 and 8 The spacer 710 shown in the figure), and similarly, a spacer ejector is not required (e.g., Figure 7 and 8 The spacer ejector 712 shown in the image.

[0046] The magnet placement device 1000 can be easily adapted to changing designs because the rotary table 1002 can be CNC controlled and its angular movement can be adjusted for the magnetic pole count using simple programming variations. In some embodiments, the magnetizing fixture 1008 can be significantly oversized to accommodate a wide range of magnet types and sizes. Furthermore, in some embodiments, the adhesive applicator 1006 can be programmed to apply different amounts of adhesive depending on the size of the magnet segment 206. In some cases, the magnet placement device 1000 can be configured for new rotor designs by simply changing the housing 714 and fixture 302 and running a new program to control the operation of the rotary table 1002 and applicator 1006.

[0047] Figure 11 and 12 Perspective and cross-sectional side views of an example rotor assembly 1100 manufactured using the techniques disclosed herein (i.e., after the magnet segments 206 have been placed within the recess 504 and the jig 302 has been removed from the back iron 404) are shown. As illustrated, the rotor assembly 1100 may include a back iron 404 and a plurality of magnet segments 206 angledly distributed on the back iron 404, wherein the outer ends 1102 of the magnet segments 206 abut against the flange 402 of the back iron 404. Figure 11 As shown in the figure, adjacent pairs of magnet segments 206 (e.g., Figure 11The magnet segments 206a and 206b can be separated by gaps 1104 corresponding to the positions of spacers 304 on the jig 302 previously attached to the back iron 404. Figure 12 As shown, the magnet segment 206 can be held in place on the back iron 404 using an adhesive applied to the interface 1202 between the bottom of the magnet segment 206 and the corresponding position on the upper surface 602 of the back iron 404 where it is placed. Since the outer end 1102 of the magnet segment contacts the flange 402, the flange 402 can be used to mitigate the centripetal force applied to the individual magnet segments 206 during rotation of the rotor assembly 1100. Therefore, in this embodiment, angular displacement of the magnet segment 206 can be prevented solely by the adhesive.

[0048] As mentioned above, in some embodiments, the jig 302 may be left in the appropriate position on the back iron 404 after it has been used to position the magnet segment 206, and may be included as an assembly of the resulting rotor assembly. Therefore, although Figure 11 and 12 Not described herein, but it should be understood that in such embodiments, the rotor assembly 1100 may additionally include a jig 302 as a component attached to the upper surface 602 of the back iron 404 (e.g., via screw 502 or other fasteners).

[0049] Furthermore, as mentioned above, in some embodiments, the flange 402 may be a component of the jig 302 rather than the back iron 404. When this jig 302 (which includes the flange 402) is left in its proper position on the back iron 404 after it has been used to position the magnet segment 206, the flange 402 of the jig 302 can be used to resolve the centripetal force exerted on the individual magnet segments 206 during rotation of the rotor assembly, similar to how a flange 402 integral with the back iron 404 can resolve such forces.

[0050] The following items describe examples of the public concepts disclosed herein.

[0051] Item A1. A method comprising: attaching a jig to a first surface of a back iron of a rotor, the jig defining at least a first recess on the first surface for receiving a magnet segment; and, after attaching the jig to the first surface, positioning the magnet segment on the first surface and within the first recess.

[0052] Item A2. The method according to Item A1, further comprising: positioning the magnet segment against the outer flange of the back iron such that the outer flange restricts the outward radial movement of the magnet segment.

[0053] Item A3. The method according to Item A2, further comprising: pressing a first end of the magnet segment against an elastic member within the first recess, such that a force applied by the elastic member pushes a second end of the magnet segment against the outer flange.

[0054] Item A4. The method according to item A3, wherein the elastic member includes an O-ring.

[0055] Item A5. The method according to item A4, wherein the elastic component includes a spring.

[0056] Item A6. The method according to any one of items A1 to A5, further comprising: applying an adhesive to at least one of the bottom of the magnet segment or a region of the first surface within the first recess before positioning the magnet segment on the first surface.

[0057] Item A7. The method according to any one of items A1 to A6, further comprising: removing the fixture from the first surface.

[0058] Item A8. The method according to Item A7, further comprising: waiting for the adhesive to at least partially cure before removing the fixture from the first surface.

[0059] Item A9. The method according to any one of items A1 to A8, wherein positioning the magnet segment on the first surface further comprises: using a pushing member of the magnet placement device to push the magnet segment along a second surface of the magnet placement device and push it onto the first surface.

[0060] Item A10. The method according to Item A9, further comprising: using the pushing member to push the magnet segment from the bottom of the magnet segment stack before using the pushing member to push the magnet segment along the second surface.

[0061] Item A11. The method according to Item A10, further comprising: using the pushing member to push a spacer disposed between the magnet segment and another magnet segment in the stack of magnet segments, together with the magnet segment, toward the first recess; and using an assembly of the magnet placement device to separate the spacer from the magnet segment before using the pushing member to push the magnet segment onto the first surface.

[0062] Item A12. The method according to any one of items A9 to A11, further comprising: magnetizing the magnet segment using a magnetizing fixture of the magnet placement device before pushing the magnet segment onto the first surface using the pushing member.

[0063] Item A13. The method according to any one of items A9 to A12, further comprising: operating a linear actuator of the magnet placement device to drive the pushing member to push the magnet segment along the second surface and push it onto the first surface.

[0064] Item A14. The method according to any one of items A9 to A13, further comprising: attaching the back iron to a rotary table before positioning the magnet segment in the first recess; and after attaching the jig to the first surface and attaching the back iron to the rotary table, operating the rotary table to rotate the first recess to align it with the end of the magnet placement device.

[0065] Item A15. The method according to any one of items A9 to A14, further comprising: applying adhesive to a region of the first surface within the first recess using the magnet placement device before using the pushing member to push the magnet segment onto the first surface.

[0066] Item A16. The method of any one of items A9 to A15, wherein the magnet placement device comprises a soft magnetic component oriented along a linear path, and the method further comprises: using the pushing component to push the magnet segment along at least a portion of the second surface such that a magnetic attraction between the magnet segment and the soft magnetic component aligns the longest axis of the magnet segment with the linear path.

[0067] Item A17. The method according to any one of items A1 to A16, wherein the jig includes at least a first hole corresponding to at least a second hole in the back iron, and the method further comprises: inserting a fastener at least partially through each of the first hole and the second hole to secure the jig to the back iron.

[0068] Item A18. The method according to any one of items A1 to A17, wherein the fixture includes a protrusion adapted to engage with a central hole of the back iron, and the method further includes: engaging the protrusion with the central hole to position the fixture on the back iron.

[0069] Item B1. An apparatus comprising: a jig adapted to be attached to a first surface of a back iron of a rotor, the jig being configured to define at least a first recess on the first surface for receiving a magnet segment when the jig is attached to the first surface.

[0070] Item B2. The device according to Item B1, wherein the fixture includes an elastic member within the first recess, the elastic member being configured and arranged to apply force to a first end of the magnet segment when the magnet segment is inserted into the first recess, thereby pushing a second end of the magnet segment against the outer flange of the back iron.

[0071] Item B3. The device according to item B2, wherein the resilient member includes an O-ring.

[0072] Item B4. The device according to item B2, wherein the elastic component comprises a spring.

[0073] Item B5. The device according to any one of items B1 to B4, in conjunction with the back iron, wherein: the fixture includes at least a first hole corresponding to at least a second hole in the back iron; and a fastener is at least partially inserted through each of the first hole and the second hole to secure the fixture to the back iron.

[0074] Item B6. The device according to any one of items B1 to B5, wherein the fixture includes a protrusion configured to mate with a central hole of the back iron.

[0075] Item B7. The device according to any one of items B1 to B6, further comprising: a magnet placement device having a second surface and a pushing member configured to push the magnet segment along the second surface and onto the first surface.

[0076] Item B8. The device according to Item B7, wherein: the magnet placement device further includes a cassette configured to hold the magnet segments stacked; and the pushing member is further configured to push the magnet segments from the bottom of the magnet segment stack before pushing the magnet segments along the second surface.

[0077] Item B9. The device according to Item B8, wherein: the pushing member is further configured to push a spacer disposed between the magnet segment and another magnet segment in the stack of magnet segments, together with the magnet segment, toward the first recess; and the magnet placement device further includes an ejection member configured to separate the spacer from the magnet segment before the pushing member pushes the magnet segment onto the first surface.

[0078] Item B10. The apparatus according to any one of items B7 to B9, wherein the magnet placement device further comprises: a magnetizing fixture configured to magnetize the magnet segment before the pushing member pushes the magnet segment onto the first surface.

[0079] Item B11. The device according to any one of items B7 to B10, wherein the magnet placement device further comprises: a linear actuator configured to drive the pushing member to push the magnet segment along the second surface and onto the first surface.

[0080] Item B12. The device according to any one of items B7 to B11, wherein the magnet placement device further comprises: a rotary table configured to have the back iron attached thereto, the rotary table being configured to rotate the back iron when the fixture is attached to the back iron, such that the first recess is aligned with the end of the magnet placement device.

[0081] Item B13. The device according to any one of items B7 to B12, wherein the magnet placement device further comprises: an adhesive applicator configured and arranged to apply adhesive to a region of the first surface within the first recess before the pushing member pushes the magnet segment onto the first surface.

[0082] Item B14. The device according to any one of items B7 to B13, wherein the magnet placement device further comprises: a soft magnetic component oriented along a linear path, the soft magnetic component being configured and arranged to align the longest axis of the magnet segment with the linear path when the pushing component pushes the magnet segment along at least a portion of the second surface.

[0083] Item C1. A method comprising: pressing a first end of a magnet segment against an elastic member located at an inner portion of a back iron of a rotor, such that a force applied by the elastic member pushes a second end of the magnet segment against a flange located at an outer portion of the back iron.

[0084] Item C2. The method according to Item C1, further comprising: attaching a fixture including the elastic member to the first surface of the back iron.

[0085] Item C3. The method according to Item C2, further comprising: applying an adhesive to at least one of the bottom of the magnet segment or a portion of the back iron to which the magnet segment will be attached, before pressing the first end of the magnet segment against the elastic member.

[0086] Item C4. The method according to any one of items C1 to C3, further comprising: removing the fixture from the first surface after the second end of the magnet segment has been pushed against the flange.

[0087] Item C5. The method according to item C4, further comprising: waiting for the adhesive to at least partially cure before removing the fixture from the first surface.

[0088] Item C6. The method according to any one of items C2 to C5, wherein the fixture defines at least a first recess on the first surface for receiving the magnet segment.

[0089] Item C7. The method according to any one of items C2 to C6, wherein the jig includes at least a first hole corresponding to at least a second hole in the back iron, and the method further comprises: inserting a fastener at least partially through each of the first hole and the second hole to secure the jig to the back iron.

[0090] Item C8. The method according to any one of items C2 to C7, wherein the fixture includes a protrusion adapted to engage with a central hole of the back iron, and the method further includes: engaging the protrusion with the central hole to position the fixture on the back iron.

[0091] Item C9. The method according to any one of items C1 to C8, further comprising: applying an adhesive to at least one of the bottom of the magnet segment or a portion of the back iron to which the magnet segment will be attached, before pressing the first end of the magnet segment against the elastic member.

[0092] Item C10. The method according to any one of items C1 to C9, further comprising: using a pushing member of the magnet placement device to push the magnet segment along the surface of the magnet placement device and push it onto the back iron, and pressing the first end of the magnet segment against the elastic member.

[0093] Item C11. The method according to Item C10, further comprising: pushing the magnet segment from the bottom of the magnet segment stack using the pushing member before pushing the magnet segment along the surface of the magnet placement device using the pushing member.

[0094] Item C12. The method according to Item C11, further comprising: using the pushing member to push a spacer disposed between the magnet segment and another magnet segment in the stack of magnet segments toward the back iron together with the magnet segment; and using an assembly of the magnet placement device to separate the spacer from the magnet segment before using the pushing member to push the magnet segment onto the back iron.

[0095] Item C13. The method according to any one of items C10 to C12, further comprising: magnetizing the magnet segment using a magnetizing fixture of the magnet placement device before pushing the magnet segment onto the back iron using the pushing member.

[0096] Item C14. The method according to any one of items C10 to C13, further comprising: operating a linear actuator of the magnet placement device to drive the pushing member to push the magnet segment along the surface of the magnet placement device and push it onto the back iron.

[0097] Item C15. The method according to any one of items C10 to C14, further comprising: applying adhesive to a portion of the back iron to which the magnet segment will be attached, using an adhesive applicator of the magnet placement device, before pushing the magnet segment onto the back iron using the pushing member.

[0098] Item C16. The method according to any one of items C10 to C15, wherein the magnet placement device includes a soft magnetic component oriented along a linear path, and the method further includes: using the pushing component to push the magnet segment along a surface of the magnet placement device such that the magnetic attraction between the magnet segment and the soft magnetic component aligns the longest axis of the magnet segment with the linear path.

[0099] Item C17. The method according to any one of items C1 to C16, wherein the elastic member comprises an O-ring.

[0100] Item C18. The method according to any one of items C1 to C16, wherein the elastic member comprises a spring.

[0101] Item D1. A method comprising: linearly pushing a magnet segment along a first surface of the magnet placement device using a pushing member of the magnet placement device, and pushing it onto a second surface of the back iron of a rotor.

[0102] Item D2. The method according to Item D1, further comprising: using the pushing member to push the magnet segment from the bottom of the magnet segment stack before using the pushing member to push the magnet segment along the first surface.

[0103] Item D3. The method according to Item D2, further comprising: using the pushing member to push a spacer disposed between the magnet segment and another magnet segment in the stack of magnet segments toward the back iron together with the magnet segment; and using an assembly of the magnet placement device to separate the spacer from the magnet segment before using the pushing member to push the magnet segment onto the second surface.

[0104] Item D4. The method according to any one of items D1 to D3, further comprising: magnetizing the magnet segment using a magnetizing fixture of the magnet placement device before pushing the magnet segment onto the second surface using the pushing member.

[0105] Item D5. The method according to any one of items D1 to D4, further comprising: operating a linear actuator of the magnet placement device to drive the pushing member to push the magnet segment along the first surface and onto the second surface.

[0106] Item D6. The method according to any one of items D1 to D5, further comprising: applying adhesive to a portion of the back iron to which the magnet segment will be attached, using an adhesive applicator of the magnet placement device, before pushing the magnet segment onto the second surface using the pushing member.

[0107] Item D7. The method according to any one of items D1 to D6, wherein the magnet placement device comprises a soft magnetic component oriented along a linear path, and the method further comprises: using the pushing component to push the magnet segment along at least a portion of the first surface such that the magnetic attraction between the magnet segment and the soft magnetic component aligns the longest axis of the magnet segment with the linear path.

[0108] Item E1. An apparatus comprising: a first surface; a pushing member; and a linear actuator configured to drive the pushing member to linearly push a magnet segment along the first surface and push it onto a second surface of a rotor's back iron.

[0109] Item E2. The device according to Item E1, further comprising: a housing configured to hold a stack of magnet segments; wherein the pushing member is configured and arranged to push the magnet segments from the bottom of the stack of magnet segments before pushing the magnet segments onto the second surface.

[0110] Item E3. The device according to Item E2, wherein: the pushing member is configured and arranged to push a spacer disposed between the magnet segment and another magnet segment in the stack of magnet segments, together with the magnet segment, toward the back iron; and the device further includes an ejection member configured to separate the spacer from the magnet segment before the pushing member pushes the magnet segment onto the second surface.

[0111] Item E4. The device according to any one of items E1 to E3, further comprising: a magnetizing fixture configured to magnetize the magnet segment before the pushing member pushes the magnet segment onto the second surface.

[0112] Item E5. The device according to any one of items E1 to E4, further comprising: a rotary table configured to have the back iron attached thereto, the rotary table being configured to rotate the back iron after the pushing member pushes the magnet segment onto the second surface.

[0113] Item E6. The device according to any one of items E1 to E5, further comprising:

[0114] An adhesive applicator is configured and arranged to apply adhesive to the area of ​​the first surface to which the magnet segment will be attached, before the pushing member pushes the magnet segment onto the first surface.

[0115] Item E7. The device according to any one of items E1 to E6, further comprising: a soft magnetic component oriented along a linear path, the soft magnetic component being configured and arranged to align the longest axis of the magnet segment with the linear path when the pushing component pushes the magnet segment along at least a portion of the first surface.

[0116] Item F1. A method comprising: linearly sliding a magnet segment along a first surface onto a second surface of a back iron of a rotor, wherein the first surface is located at or above a flange extending upward from the second surface at an outer edge of the back iron, such that the magnet segment is capable of sliding over the flange before sliding onto the second surface.

[0117] Item F2. The method according to Item F1 further includes: positioning the magnet segment against the flange such that the flange restricts the outward radial movement of the magnet segment.

[0118] Item F3. The method according to item F1 or F2, wherein the flange is integral with the back iron.

[0119] Item F4. The method according to any one of items F1 to F3, further comprising: attaching a jig to the second surface before sliding the magnet segment onto the second surface, the jig defining at least a first recess on the second surface for receiving the magnet segment.

[0120] Item F5. The method according to Item F4, further comprising: pressing a first end of the magnet segment against an elastic member within the first recess, such that a force applied by the elastic member pushes a second end of the magnet segment against the flange.

[0121] Item F6. The method according to item F5, wherein the elastic member includes an O-ring.

[0122] Item F7. The method according to any one of items F4 to F6, further comprising: applying an adhesive to at least one of the bottom of the magnet segment or a region of the second surface within the first recess before sliding the magnet segment onto the second surface.

[0123] Item F8. The method according to any one of items F4 to F7, further comprising: removing the fixture from the second surface.

[0124] Item F9. The method according to Item F8 further includes: waiting for the adhesive to at least partially cure before removing the fixture from the second surface.

[0125] Item F10. The method according to any one of items F4 to F9, further comprising: using a pushing member of a magnet placement device to push the magnet segment along the first surface and push it onto the second surface within the first recess.

[0126] Item F11. The method according to item F10, further comprising: pushing the magnet segment from the bottom of the magnet segment stack using the pushing member before pushing the magnet segment along the first surface using the pushing member.

[0127] Item F12. The method according to Item F11, further comprising: using the pushing member to push a spacer disposed between the magnet segment and another magnet segment in the stack of magnet segments, together with the magnet segment, toward the first recess; and using an assembly of the magnet placement device to separate the spacer from the magnet segment before using the pushing member to push the magnet segment onto the second surface.

[0128] Item F13. The method according to any one of items F10 to F12, further comprising: magnetizing the magnet segment using a magnetizing fixture of the magnet placement device before pushing the magnet segment onto the second surface using the pushing member.

[0129] Item F14. The method according to any one of items F10 to F13, wherein the magnet placement device comprises a soft magnetic component oriented along a linear path, and the method further comprises: using the pushing component to push the magnet segment along at least a portion of the first surface such that the magnetic attraction between the magnet segment and the soft magnetic component aligns the longest axis of the magnet segment with the linear path.

[0130] Item F15. The method according to any one of items F10 to F14, further comprising: attaching the back iron to a rotary table before sliding the magnet segment along the first surface and onto the second surface; and after attaching the jig to the second surface and attaching the back iron to the rotary table, operating the rotary table to rotate the first recess to align it with the end of the magnet placement device.

[0131] Item F16. The method according to any one of items F4 to F15, wherein the flange is an assembly of the fixture.

[0132] Item G17. A method comprising: pressing a first end of a magnet segment against an elastic member located at an inner portion of a back iron of a rotor, such that a force applied by the elastic member pushes a second end of the magnet segment against a flange located at an outer portion of the back iron.

[0133] Item G18. The method according to Item G17, further comprising: attaching a jig containing the elastic member to the surface of the back iron to which the magnet segment will be attached.

[0134] Item G19. The method according to Item G17 or G18 further comprises: applying an adhesive to at least one of the bottom of the magnet segment or the surface of the back iron to which the magnet segment will be attached, before pressing the first end of the magnet segment against the elastic member.

[0135] Item G20. The method according to any one of items G17 to G19, wherein the elastic member comprises an O-ring.

[0136] Therefore, given that several aspects of at least one embodiment have been described, it should be understood that various changes, modifications, and improvements will readily occur to those skilled in the art. Such changes, modifications, and improvements are intended to be part of and within the spirit and scope of this disclosure. Therefore, the foregoing description and accompanying drawings are merely examples.

[0137] The various aspects of this disclosure may be used individually, in combination, or in a variety of arrangements not explicitly discussed in the embodiments described above, and therefore this application is not limited to the details and arrangements of the components set forth in the foregoing description or illustrated in the drawings. For example, an aspect described in one embodiment may be combined in any way with aspects described in other embodiments.

[0138] Furthermore, the disclosed aspects can be embodied as methods, and examples of said methods have been provided. Actions performed as part of the method can be ordered in any suitable manner. Therefore, embodiments can be constructed in which actions are performed in an order different from that described (which may include the simultaneous execution of some actions, even if shown as sequential actions in the illustrative embodiments).

[0139] The use of ordinal terms (e.g., "first", "second", "third", etc.) to modify a technical element in the claims does not imply any priority, order, or chronological sequence of actions of one technical element over another, but is merely used as a label to distinguish one claimed element with a specific name from another element with the same name (but using ordinal terms).

[0140] Furthermore, the phrases and terms used herein are for descriptive purposes only and should not be considered restrictive. The use of “comprising,” “including,” “having,” “containing,” “involving,” and variations thereof in this document is intended to cover the items listed thereafter and their equivalents, as well as additional items.

Claims

1. A method for placing a magnet segment, comprising: A jig containing an elastic member is attached to the back iron of the rotor, such that the elastic member is positioned at an internal portion of the back iron; After attaching the jig to the back iron, the magnet segment is moved relative to the back iron so that the magnet segment contacts the elastic member; and The first end of the magnet segment is pressed against the elastic member, such that the force applied by the elastic member pushes the second end of the magnet segment against the flange located on the outer portion of the back iron.

2. The method according to claim 1, further comprising: Before pressing the first end of the magnet segment against the elastic member, an adhesive is applied to at least one of the bottom of the magnet segment or the surface of the back iron to which the magnet segment will be attached.

3. The method according to claim 1, wherein the elastic component comprises an O-ring.

4. The method according to claim 1, wherein: Moving the magnet segment relative to the back iron includes sliding the magnet segment linearly along a first surface and onto a second surface of the back iron, so that the magnet segment contacts the elastic member; The flange extends upward from the second surface at the outer portion; and The first surface is positioned at or above the flange so that the magnet segment can slide above the flange before sliding onto the second surface.

5. The method of claim 4, further comprising: The pushing component of the magnet placement device pushes the magnet segment along the first surface and onto the second surface.

6. The method of claim 5, further comprising: Before using the pushing member to push the magnet segment along the first surface, the pushing member is used to push the magnet segment from the bottom of the magnet segment stack.

7. The method of claim 6, further comprising: The pushing component is used to push the spacer placed between the magnet segment and another magnet segment in the stack of magnet segments toward the back iron together with the magnet segment; and Before using the pushing component to push the magnet segment onto the second surface, the spacer is separated from the magnet segment using the components of the magnet placement device.

8. The method of claim 5, further comprising: Before pushing the magnet segment onto the second surface using the pushing component, the magnet segment is magnetized using the magnetizing fixture of the magnet placement device.

9. The method of claim 5, wherein the magnet placement device comprises a soft magnetic component oriented along a linear path, and the method further comprises: Using the pushing member, the magnet segment is pushed along at least a portion of the first surface such that the magnetic attraction between the magnet segment and the soft magnetic member aligns the longest axis of the magnet segment with the linear path.

10. The method of claim 4, wherein attaching the jig to the back iron comprises: The jig is attached to the second surface such that the jig defines at least a first recess on the second surface for receiving the magnet segment.

11. The method of claim 10, wherein: The elastic member is arranged on the fixture such that when the fixture is attached to the second surface, a portion of the elastic member is positioned within the first recess at the inner portion of the back iron.

12. The method of claim 11, wherein the elastic member comprises an O-ring.

13. The method of claim 10, further comprising: Before sliding the magnet segment onto the second surface, an adhesive is applied to at least one of the bottom of the magnet segment or the area of ​​the second surface within the first recess.

14. The method of claim 13, further comprising: After the magnet segment is slid onto the second surface, the fixture is removed from the second surface.

15. The method of claim 14, further comprising: Before removing the fixture from the second surface, wait for the adhesive to cure at least partially.

16. The method of claim 10, further comprising: The magnet segment is pushed along the first surface using the pushing component of the magnet placement device and pushed onto the second surface within the first recess.

17. The method of claim 16, further comprising: Before using the pushing member to push the magnet segment along the first surface, the pushing member is used to push the magnet segment from the bottom of the magnet segment stack.

18. The method of claim 17, further comprising: The pushing component is used to push the spacer placed between the magnet segment and another magnet segment in the stack of magnet segments, together with the magnet segment, toward the first recess; and Before using the pushing component to push the magnet segment onto the second surface, the spacer is separated from the magnet segment using the components of the magnet placement device.

19. The method of claim 16, further comprising: Before pushing the magnet segment onto the second surface using the pushing component, the magnet segment is magnetized using the magnetizing fixture of the magnet placement device.

20. The method of claim 16, wherein the magnet placement device comprises a soft magnetic component oriented along a linear path, and the method further comprises: Using the pushing member, the magnet segment is pushed along at least a portion of the first surface such that the magnetic attraction between the magnet segment and the soft magnetic member aligns the longest axis of the magnet segment with the linear path.

21. The method of claim 16, further comprising: The back iron is attached to the rotary table before the magnet segment slides along the first surface and onto the second surface; and After attaching the fixture to the second surface and attaching the back iron to the rotary table, the rotary table is operated to rotate the first recess so as to align it with the end of the magnet placement device.

22. The method of claim 10, wherein the flange is an assembly of the fixture.

23. The method according to claim 1, wherein: The flange is configured and arranged to restrict the outward radial movement of the magnet segment as the rotor rotates about the rotation axis.

24. The method according to claim 1, wherein the flange and the back iron are integral.

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