Halbach array type inner and outer diameter coaxial lossless magnetic circuit assembly

Abstract

This invention belongs to the field of motor technology, specifically relating to a Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters. This invention provides a Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters, aiming to solve the problems of unreasonable magnetic ring structure and gaps between magnets in existing Hellbeck array motors. A Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters includes at least two first magnets and at least two second magnets, with the first and second magnets alternately arranged in a Hellbeck configuration. This invention significantly improves upon the shortcomings of traditional gap-arranged arrangements by forming a completely closed magnetic circuit through alternating close contact (without gaps) between the first and second magnets. Furthermore, the inner and outer diameters are produced with zero errors as per the drawings. The close contact of the magnets eliminates magnetic field fluctuations caused by gaps, resulting in a more uniform magnetic field distribution, effectively reducing torque pulsation, making the motor run more smoothly, and reducing vibration and noise, making it particularly suitable for applications requiring high precision or quiet operation.

Description

Technical Field

[0001] This invention belongs to the field of motor technology, specifically relating to a Heilbeck array-type coaxial lossless magnetic circuit assembly. Background Technology

[0002] The Halbach array is a special arrangement of permanent magnets that optimizes the magnetic field distribution to achieve a strong magnetic field on one side and a weak magnetic field on the other side in a motor, thereby improving motor efficiency or reducing magnetic leakage.

[0003] In existing technologies, the magnets of a motor are typically attached to the inner circumferential wall of a magnetic ring at certain intervals (gap exists between the magnets). The presence of these gaps has the following negative effects: The gaps between the magnets lead to uneven magnetic field distribution, especially in the gap areas where magnetic field "dips" or "fluctuations" may occur. This reduces the ideal magnetic field distribution of the Hellbeck array, affecting the smoothness of the motor's torque output and potentially increasing torque ripple, leading to vibration and noise. The gaps reduce the effective magnet coverage area, resulting in an overall decrease in magnetic field strength. This reduces the motor's power density and efficiency, especially noticeable in applications requiring high magnetic field strength (such as high-speed or high-torque motors).

[0004] When there are gaps between magnets, their fixation may rely on adhesives or mechanical clamping. Under conditions of high-speed rotation or temperature changes, the adhesive may age or fail, causing magnet displacement or even detachment, affecting the reliability of motor operation. Gaps can lead to discontinuous magnetic field distribution within the magnetic ring, potentially inducing localized eddy currents (especially at high speeds). Eddy current losses generate heat, reducing motor efficiency and possibly requiring additional cooling measures.

[0005] One of the design goals of the Hellbeck array was to reduce magnetic leakage. However, if the magnets are not arranged continuously (with excessively large gaps), some magnetic fields may not be effectively guided, increasing magnetic leakage and weakening its magnetic field concentration effect. Precise control of magnet spacing and placement is required during assembly; otherwise, assembly errors may lead to magnetic field asymmetry, affecting motor performance. This increases manufacturing costs and process complexity. Summary of the Invention

[0006] This invention provides a Hellbeck array type coaxial lossless magnetic circuit assembly, which aims to solve the problems of unreasonable motor magnetic ring structure and gaps between magnets in the prior art.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A Helbeck array-type coaxial non-destructive magnetic circuit assembly includes at least two first magnets and at least two second magnets, wherein the first magnets and second magnets are alternately arranged in a Helbeck configuration, and the first magnets and second magnets in contact with each other form a tight contact that completely seals the magnetic circuit.

[0008] A further improved solution: The second magnet is a magnet with elastic deformation function. The second magnet is installed between the two first magnets in an interference fit manner by means of elastic deformation, so that the first magnets and the second magnets that are in contact with each other form a tight contact.

[0009] Based on the above technical solution: the elastic deformation of the second magnet allows it to form a gapless, tight contact with the first magnet, eliminating magnetic field fluctuations caused by traditional gaps. The elastic deformation of the second magnet creates an interference fit, eliminating the need for adhesives or mechanical clamps and avoiding magnet loosening problems caused by adhesive aging or thermal deformation. The elastic deformation capability can compensate for manufacturing tolerances, adapt to dimensional changes at different temperatures, and improve long-term operational stability.

[0010] A further improved solution: The first magnet is a rare-earth magnet.

[0011] Based on the above technical solutions: rare earth magnets (such as neodymium iron boron) have extremely high remanence and coercivity, which can provide magnetic field strength far exceeding that of traditional magnets, significantly improving motor power density and torque output, and are suitable for high-speed and high-load scenarios.

[0012] A further improved solution: The first magnet is a neodymium iron boron magnet.

[0013] Based on the above technical solutions, neodymium iron boron (NdFeB) is currently the permanent magnet material with the highest magnetic energy product, providing extremely strong magnetic field strength. This significantly improves the power density and torque output of motors, making it particularly suitable for high-power, high-efficiency applications. Under the same magnetic field strength, the volume of a NdFeB magnet is only 1 / 5 to 1 / 10 that of a ferrite magnet, facilitating compact motor design and reducing overall weight.

[0014] A further improved solution: The second magnet is a soft magnetic material made of plastic.

[0015] Based on the above technical solutions: Plastic soft magnets possess excellent elastic deformation capabilities and can form a gapless, tight contact with the first magnet (such as neodymium iron boron) through an interference fit, ensuring a completely sealed magnetic circuit and significantly reducing magnetic field fluctuations and leakage. Compared to metal magnets, plastic materials have lower density, reducing overall weight, and possess moisture resistance and chemical corrosion resistance, expanding the applicability of the motor in harsh environments.

[0016] A further improved solution: A receiving groove for mounting the second magnet is formed between two adjacent first magnets along the circumference of the magnetic ring device. The width of the receiving groove on the side closer to the center of the magnetic ring device is smaller than the width of the receiving groove on the side farther from the center of the magnetic ring. The shape of the second magnet is adapted to the shape of the receiving groove.

[0017] Based on the above technical solution: the trapezoidal or wedge-shaped structure (narrower inside and wider outside) of the receiving groove matches the shape of the second magnet, generating a self-locking effect during radial assembly. This ensures a tight, gapless contact between the first and second magnets, effectively sealing the magnetic circuit and eliminating magnetic field fluctuations and leakage problems caused by traditional gaps. The radial assembly method simplifies the installation process, eliminating the need for precise gap adjustments; the geometric constraints of the receiving groove prevent magnet displacement, maintaining stable contact even under high-speed rotation or temperature changes, thus improving long-term reliability.

[0018] A further improved solution: A receiving groove for mounting the second magnet is formed between two adjacent first magnets along the circumference of the magnetic ring device. The width of the receiving groove on the side closer to the center of the magnetic ring device is greater than the width of the receiving groove on the side farther from the center of the magnetic ring. The shape of the second magnet is adapted to the shape of the receiving groove.

[0019] Based on the above technical solution: the receiving groove adopts a trapezoidal structure that is wider on the inside and narrower on the outside (with a larger width near the center), which precisely matches the shape of the second magnet. During radial assembly, the second magnet naturally presses against the narrow end of the groove under the action of centrifugal force, forming a mechanical self-locking effect, ensuring that the magnets are in close contact without gaps, achieving complete closure of the magnetic circuit, and significantly reducing magnetic field leakage and fluctuations.

[0020] A further improved solution: Both the first magnet and the second magnet are rare-earth magnets.

[0021] Based on the above technical solution: the high remanence of rare-earth magnets results in a significant magnetic field superposition effect between adjacent magnets, leading to a marked increase in the magnetic field strength on the working side and a substantial improvement in motor power density and torque output. The close contact of the two rare-earth materials achieves near-zero gap magnetic circuit sealing, reducing magnetic leakage by more than 60%, improving the uniformity of magnetic field distribution, and effectively reducing torque pulsation and eddy current losses.

[0022] A further improved solution: Both the first magnet and the second magnet are neodymium iron boron magnets.

[0023] Based on the above technical solution: the high remanence of neodymium iron boron magnets makes the magnetic field superposition effect significant, increasing the magnetic field strength on the working side by more than 40%, which significantly improves the power density and torque output capability of the motor.

[0024] A further improved solution: The magnetic ring device further includes a housing, and both the first magnet and the second magnet are disposed within the housing.

[0025] Based on the above technical solution: the outer casing provides a physical barrier for the internal magnets, effectively preventing external impacts, dust, or liquid intrusion, improving the device's durability in harsh environments, and extending its service life. The outer casing can confine magnetic leakage, reducing electromagnetic interference to surrounding components, while simultaneously enhancing the concentration of the magnetic field on the working side.

[0026] The beneficial effects of this invention are as follows: This invention significantly improves upon the shortcomings of traditional gap-type arrangements by forming a completely closed magnetic circuit through alternating close contact (without gaps) between the first and second magnets. The close contact of the magnets eliminates magnetic field fluctuations caused by gaps, resulting in a more uniform magnetic field distribution, effectively reducing torque pulsation, making the motor run more smoothly, and reducing vibration and noise. It is especially suitable for applications requiring high precision or quiet operation (such as medical equipment and precision instruments).

[0027] The maximized magnet coverage area significantly improves magnetic field strength, enhancing the motor's power density and energy conversion efficiency. This makes it suitable for applications requiring stringent magnetic field strength, such as high-speed and high-torque motors. Direct contact between magnets reduces reliance on adhesives or mechanical fasteners, avoiding the risk of magnet displacement due to adhesive aging or temperature changes, and improving long-term operational stability.

[0028] The closed magnetic circuit design reduces magnetic field discontinuities, minimizes eddy current losses and heat generation, and effectively suppresses magnetic leakage, making the magnetic field concentration effect closer to the theoretical performance of an ideal Hellbeck array. It eliminates the need for precise gap control, reducing assembly process complexity and saving manufacturing costs. Furthermore, it avoids magnetic field asymmetry problems caused by assembly errors, enabling error-free production of both inner and outer diameters according to the drawings.

[0029] The closed magnetic circuit design with close magnet contact significantly optimizes magnetic field performance, reliability, and manufacturing process, providing a reliable solution for the miniaturization and high efficiency of high-performance motors. Attached Figure Description

[0030] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For users of ordinary skills in the art, other related drawings can be obtained from these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of a Heilbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to the present invention.

[0032] Figure 2This is a front view of a Helbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to the present invention, which includes two first magnets and two second magnets.

[0033] Figure 3 This is a front view of a Helbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to the present invention, which includes eight first magnets and eight second magnets.

[0034] Figure 4 This is a schematic diagram of the first type of receiving slot in a Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to the present invention.

[0035] Figure 5 This is a schematic diagram of the second form of the receiving slot in a Heilbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to the present invention.

[0036] Explanation of the labels in the diagram: 1-First magnet; 2-Second magnet; 3-Outer shell. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention. All other embodiments obtained by users of the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0038] refer to Figures 1 to 3 A Helbeck array-type coaxial non-destructive magnetic circuit assembly includes at least two first magnets 1 and at least two second magnets 2, wherein the first magnets 1 and the second magnets 2 are alternately arranged in a Helbeck configuration, and the first magnets 1 and the second magnets 2 that are in contact with each other form a tight contact that completely seals the magnetic circuit.

[0039] Specifically: There can be two first magnets 1 and two second magnets 2. Alternatively, there can be eight first magnets 1 and eight second magnets 2. The number of first magnets 1 and second magnets 2 is not limited and can be determined according to actual needs.

[0040] Wherein: the second magnet 2 is a magnet with elastic deformation function. The second magnet 2 is installed between the two first magnets 1 by means of elastic deformation in an interference fit, so that the first magnets 1 and the second magnet 2 that are in contact with each other form a tight contact. The first magnet 1 is a rare earth magnet, or the first magnet 1 is a neodymium iron boron magnet. The second magnet 2 is a soft magnetic material of plastic type. The second magnet 2 can also be a soft or injection-molded magnetic material, such as injection-molded magnets, rubber (elastic expansion type) magnetic strips, etc. Rubber injection-molded magnetic strips have strong plasticity and are suitable for complex shapes.

[0041] This solution is applicable to continuous and fully circular high-precision magnetic rings in any Hellbeck array. The second magnet 2 has elastic deformation capabilities, enabling installation with negligible manufacturing tolerance expansion or soft magnet injection molding. The second magnet 2 is an elastic, injection-molded magnet similar to a plastic magnetic material, enabling high-precision mass production of Hellbeck array rings. This installation method utilizing the elastic deformation of the second magnet 2 can be installed without affecting the existing motor structure, allowing for large-scale industrial production.

[0042] This solution improves motor efficiency (by 5%-30%) without altering the motor structure and reduces back electromotive force, thus lowering noise. Furthermore, it effectively reduces motor heat generation and manufacturing costs. The level of sparking in brushed motors is reduced exponentially, extending service life.

[0043] refer to Figures 4 to 5 In this design, the first magnet 1 and the second magnet 2 can be made of the same material. For example, a receiving groove for mounting the second magnet 2 is formed between two adjacent first magnets 1 along the circumference of the magnetic ring device. A first form of the receiving groove is that the width A of the receiving groove near the center of the magnetic ring device is smaller than the width B of the receiving groove away from the center of the magnetic ring, and the shape of the second magnet 2 matches the shape of the receiving groove. Alternatively, a receiving groove for mounting the second magnet 2 is formed between two adjacent first magnets 1 along the circumference of the magnetic ring device. A second form of the receiving groove is that the width C of the receiving groove near the center of the magnetic ring device is larger than the width D of the receiving groove away from the center of the magnetic ring, and the shape of the second magnet 2 matches the shape of the receiving groove. This solution uses radial assembly to create a tight contact between the contacting first magnets 1 and second magnets 2, ensuring a completely closed magnetic circuit. Both the first magnet 1 and the second magnet 2 are rare-earth magnets. Both the first magnet 1 and the second magnet 2 are neodymium iron boron magnets. The first magnet 1 and the second magnet 2 are made of the same material and are assembled using a radial tilting method with the magnetic ring center as the reference. This effectively ensures the outer diameter and magnetic strength, and the magnetic circuit is completely enclosed with no open circuits. Both the first magnet 1 and the second magnet 2 can be made of Y30 ferrite. Y30 ferrite has the advantages of high cost-effectiveness, excellent magnetic properties, and suitability for mass production. This solution achieves high-precision manufacturing without changing the shape and accuracy (±0.01mm) of the stator or rotor of existing motor models, improving motor efficiency (5%-30% improvement depending on different parameters).

[0044] The technical solution of the present invention is further illustrated below with specific application examples. The Halebeck effect magnetic field distribution characteristics are as follows: the magnetic field strength decreases with increasing axial distance, and the magnetic field is strongest in the central region of the motor (0-20mm). The magnetic ring device arranged in a Halebeck pattern may further include a housing, in which the first magnet and the second magnet are both disposed. The specific parameters of the motor using this magnetic ring device are: motor outer diameter: 92mm, motor inner diameter: 80mm (hypothetical value), motor height: 75mm, air gap: 1mm, number of pole pairs: 4, number of magnets: 8.

[0045] The relevant parameters of the first magnet and the second magnet are shown in the table below: parameter Ferrite Y30 Rubber injection molded magnetic strip Remanence Br 0.420T 0.280T Coercivity Hcb 320kA / m 200kA / m Maximum magnetic energy product 32kJ / m³ 18kJ / m³ Estimating the air gap magnetic field 252mT 168mT Cost Index 1.0 0.7 Magnetic field enhancement effect (advantages of the Heilbeck array): Peak enhancement ratio: 1.50× (50% improvement), Average enhancement ratio: 1.22× (22% improvement), Magnetic field uniformity improvement: approximately 50%.

[0046] The magnetic field data at key locations are shown in the table below: Axial position (mm) Air gap magnetic field (mT) Surface magnetic field (mT) Enhancement ratio 0.0 2.39 2.27 1.50 10.0 2.23 2.13 1.33 20.0 1.90 1.82 1.21 30.0 1.53 1.48 1.14 40.0 1.15 1.12 1.09 46.0 1.00 0.98 1.07 The above data demonstrates that the Hellbeck array improves the magnetic field strength by approximately 7-50% compared to traditional radial magnetization methods, with the most significant enhancement effect observed in the central region. The working principle of this embodiment: The first and second magnets are arranged alternately according to the rules of the Hellbeck array (e.g., alternating N poles, oblique magnetization, and S poles), and the magnetic field direction changes continuously through close contact between the magnets. This arrangement causes the magnetic field to be superimposed and strengthened on one side of the device (working side) and canceled and weakened on the other side (non-working side), forming an ideal distribution of a strong magnetic field on one side. The gapless contact between the magnets eliminates the magnetic field interruption caused by traditional gaps, and the magnetic field lines are continuously conducted between adjacent magnets, forming a closed loop. This design reduces magnetic leakage and magnetic field fluctuations, making the magnetic field distribution more uniform, thereby reducing torque pulsation and eddy current losses. The direct contact and close arrangement between the magnets reduce the impact of assembly errors on the symmetry of the magnetic field, ensuring the stability of the magnetic field performance during long-term operation.

[0047] This invention is not limited to the above-mentioned optional embodiments. Under the premise of non-contradiction, the various solutions can be combined arbitrarily. Anyone can derive other forms of products under the guidance of this invention. However, no matter what changes are made in their shape or structure, all technical solutions that fall within the scope of the claims of this invention are within the protection scope of this invention.

Claims

1. A Helbeck array-type coaxial lossless magnetic circuit assembly, characterized in that: It includes at least two first magnets and at least two second magnets, the first magnets and the second magnets are alternately arranged in a Helbeck pattern, and the first magnets and the second magnets that are in contact with each other form a tight contact that completely closes the magnetic circuit.

2. The Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to claim 1, characterized in that: The second magnet is a magnet with elastic deformation function. The second magnet is installed between the two first magnets in an interference fit manner by means of elastic deformation, so that the first magnets and the second magnets that are in contact with each other form a tight contact.

3. The Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to claim 1, characterized in that: The first magnet is a rare earth magnet.

4. The Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to claim 1, characterized in that: The first magnet is a neodymium iron boron magnet.

5. A Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to any one of claims 1 to 4, characterized in that: The second magnet is a soft magnetic material made of plastic.

6. A Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to claim 1, characterized in that: A receiving groove for mounting the second magnet is formed between two adjacent first magnets along the circumference of the magnetic ring device. The width of the receiving groove on the side closer to the center of the magnetic ring device is smaller than the width of the receiving groove on the side farther from the center of the magnetic ring. The shape of the second magnet is adapted to the shape of the receiving groove.

7. A Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to claim 1, characterized in that: A receiving groove for mounting the second magnet is formed between two adjacent first magnets along the circumference of the magnetic ring device. The width of the receiving groove on the side closer to the center of the magnetic ring device is greater than the width of the receiving groove on the side farther from the center of the magnetic ring. The shape of the second magnet is adapted to the shape of the receiving groove.

8. A Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to claim 6 or 7, characterized in that: Both the first magnet and the second magnet are rare earth magnets.

9. A Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to claim 6 or 7, characterized in that: Both the first magnet and the second magnet are neodymium iron boron magnets.

10. A Hellbeck array-type coaxial lossless magnetic circuit assembly with inner and outer diameters according to claim 1, characterized in that: The magnetic ring device also includes a housing, and both the first magnet and the second magnet are disposed within the housing.

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