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

Abstract

The system (101) for magnetizing one or more rare earth metals (110) includes one or more laminated sheets (114). The one or more laminated sheets (114) are stacked together to form a laminated block (116). The one or more laminated blocks (116) are stacked to form a 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 for disposing the one or more rare earth metals (110) in an unmagnetized state. The system (101) further includes a magnetizing unit (122). The magnetizing unit (122) includes one or more magnetized surfaces (124) and one or more magnetizing windings (126). The one or more magnetizing surfaces (124) magnetize the one or more rare earth metals (110) of the rotor assembly (100) by passing a predetermined supply therethrough.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION

[0002] Embodiments herein relate generally to rotor assemblies of electric machines, and more particularly to systems and methods for magnetizing one or more rare earth metals to construct rotor assemblies of electric machines. This application is based on and claims priority to Indian Provisional Application No. 202241070714, filed December 7, 2022, the disclosure of which is incorporated herein by reference. [Background technology]

[0002] Currently, automobile manufacturers, especially those specializing in electric vehicles, prefer permanent magnet (PM) electric machines due to their extremely high starting torque. In PM electric machines, the rotor winding is replaced with a permanent magnet, as a continuous supply of electrical energy is required to generate and maintain the magnetic field. Furthermore, the rotor winding has a complex and difficult structure, requiring extremely high precision when inserted into the magnetic slots of the rotor assembly.

[0003] Traditionally, during rotor assembly in PM electric machines, permanent magnets (pre-magnetized) are inserted into multiple slots in the rotor assembly. The slots are arranged around the rotor shaft and act as housings for the permanent magnets. Because the rotor assembly is made of magnetic material, the permanent magnets are attracted to the rotor assembly. As a result, assembling the permanent magnets into the rotor assembly is complex and can lead to worker fatigue. The assembly process requires numerous automotive tools and techniques (for holding and pressing) to perfectly align the permanent magnets into the multiple slots, increasing the cost and complexity of the system.

[0004] Permanent magnets are very sensitive to heat and vibration. When exposed to heat, they become demagnetized. This requires special care and makes the transportation and handling process difficult. During assembly, trained professionals are required because the poles of the permanent magnets can be misoriented. Furthermore, an additional mechanism is required to separate the permanent magnets.

[0005] In existing systems, automakers avoid using permanent magnets (pre-magnetized) in the rotor assembly of electric machines. Instead of using permanent magnets, automakers use liquid magnetic material filling and molding into the magnetic slots of the rotor assembly. At the same time, filling and molding the liquid magnetic material requires molding machines such as injection molding machines, which increases the system cost. Furthermore, when filling and molding the liquid magnetic material, attention must be paid to many parameters, such as orientation strength, application time, and application method.

[0006] In other existing systems, the rotor assembly is constructed as a single component, resulting in high eddy current losses. In other existing systems, the permanent magnets heat up due to heat generated by the rotation of the rotor assembly. In other existing systems, the magnets are fragile, so the rotor assembly is constructed as one or more components, and then the one or more components are assembled to form the rotor assembly. This method makes it difficult to align the same poles (NN or SS) of the magnets integrally along the longitudinal axis of the rotor assembly.

[0007] Furthermore, in other existing systems, automakers use a multi-stage magnetization approach in which all north poles (N) are magnetized in different magnetization steps and all south poles (S) are magnetized in different magnetization steps. Multi-stage magnetization results in uneven Tesla values ​​for the north poles (N) and south poles (S) of the rotor assembly. A rotor assembly with uneven Tesla values ​​leads to unbalanced polarization, wear issues, voltage harmonics, and low efficiency. Furthermore, uneven Tesla values ​​can lead to torque fluctuations in the rotor assembly, which can generate vibrations. Traditional and existing systems are not efficient enough to solve the above challenges of configuring electric machines.

[0008] Therefore, there remains a need for improved systems and methods for magnetizing one or more rare earth metals for constructing rotor assemblies for electric machines and for addressing the aforementioned challenges. Summary of the Invention [Problem to be solved by the invention]

[0009] In view of the above, one embodiment of the present specification provides a system for magnetizing one or more rare earth metals to construct a rotor assembly. The system includes one or more stacked sheets. The one or more stacked sheets are stacked together to construct a stacked block. The one or more stacked blocks are stacked to construct the 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 mechanically configured to provide a predetermined space for disposing one or more unmagnetized rare earth metals. The system further includes a magnetizing unit. The magnetizing unit includes one or more magnetizing surfaces and one or more magnetizing windings. The one or more magnetizing surfaces are configured to magnetize the one or more rare earth metals of the rotor assembly by passing a predetermined supply through the one or more magnetizing windings.

[0010] In one embodiment, the one or more magnetizing windings include different polarities, and the one or more magnetizing windings with different polarities are configured to magnetize one or more rare earth metals such that one or more adjacent magnetic poles of the rotor assembly are opposite (NS, SN).

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

[0012] In yet another embodiment, the first predetermined shape and the second predetermined shape are configured to be aligned with one another to avoid misalignment of the rotor assembly with the magnetizing unit, and in yet another embodiment, one or more surfaces of the rotor assembly are positioned a predetermined distance from one or more magnetizing surfaces of the magnetizing unit.

[0013] In yet another embodiment, the predetermined distance varies based on the circumference of the rotor assembly, the first predetermined shape of the one or more surfaces, the second predetermined shape of the one or more magnetized surfaces, and the orientation of the one or more rare earth metals.

[0014] In yet another embodiment, the magnetizing unit further includes one or more magnetic flux concentrators configured to separate one or more magnetized surfaces of the north pole (N) from one or more magnetized surfaces of the south pole (S). The one or more surfaces of the rotor assembly, the one or more magnetic flux concentrators, and the one or more magnetized surfaces of the magnetizing unit are configured to focus magnetic flux lines from the magnetizing unit onto one or more rare earth metals disposed on one or more slots of the rotor assembly.

[0015] In yet another embodiment, the magnetizing unit is configured to uniformly magnetize one or more rare earth metals of the rotor assembly at a time such that one or more adjacent magnetic poles of the rotor assembly are opposite (NS, SN).

[0016] In another aspect, a method for magnetizing one or more rare earth metals to construct a rotor assembly is provided, comprising the steps of: (a) stacking one or more laminate sheets to construct a laminate block; (b) positioning one or more rare earth metals in one or more slots; (c) bonding one or more rare earth metals to the one or more slots; (d) stacking one or more laminate blocks in the presence of a rotor shaft using one or more joining processes to construct a rotor assembly having one or more balancing rings; (e) balancing the rotor assembly, which includes one or more surfaces on its periphery; and (f) placing the rotor assembly in a magnetizing unit, which includes one or more magnetized surfaces and (g) positioning the first predetermined shape and the second predetermined shape in a manner that avoids misalignment of the rotor assembly and the magnetizing unit; (h) positioning one or more surfaces of the rotor assembly a predetermined distance from one or more magnetizing surfaces of the magnetizing unit; (i) concentrating magnetic flux lines from the magnetizing unit onto one or more rare earth metals using one or more surfaces of the rotor assembly, one or more magnetic flux concentrators, and one or more magnetizing surfaces of the magnetizing unit; and (j) magnetizing one or more rare earth metals by passing a predetermined supply through one or more magnetizing windings.

[0017] In another embodiment, the method further comprises the step of: magnetizing one or more rare earth metals using one or more magnetizing windings of different polarity such that one or more adjacent magnetic poles of the rotor assembly are opposite (NS, SN).

[0018] In another embodiment, the method further comprises the step of: separating one or more magnetized surfaces of the North Pole (N) from one or more magnetized surfaces of the South Pole (N) using one or more magnetic flux concentrators.

[0019] In yet another embodiment, the method further comprises the following steps: using a magnetizing unit, uniformly magnetizing one or more rare earth metals of the rotor assembly at a time so that one or more adjacent magnetic poles of the rotor assembly are opposite (NS, SN).

[0020] In yet another embodiment, the one or more joining processes include riveting, welding, clamping, interlocking, gluing, and fastening.

[0021] These and other aspects of the embodiments herein will be better understood and appreciated when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments and numerous specific details thereof, is given by way of illustration and not limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications. [Brief explanation of the drawings]

[0022] The embodiments herein will be better understood from the following detailed description taken in conjunction with the drawings in which: [Figure 1A] FIG. 1 illustrates a system for magnetizing one or more rare earth metals to form a rotor assembly according to an embodiment of the present disclosure. [Figure 1B] FIG. 1 is a top view illustrating a rotor assembly with a magnetizing unit according to an embodiment of the present disclosure. [Figure 1C] 1 is a partial schematic cross-sectional view illustrating a rotor assembly with a magnetizing unit according to an embodiment of the present disclosure. [Figure 2A] 1 is a top view illustrating one or more stacked sheets of a rotor assembly according to an embodiment herein. [Figure 2B] FIG. 1 is an isometric view illustrating a stacked block of a rotor assembly according to an embodiment of the present disclosure. [Figure 2C] FIG. 1 is an isometric view illustrating one or more stacked blocks of a rotor assembly according to an embodiment herein. [Figure 3] FIG. 1 is an exploded view illustrating an electric machine of a system according to an embodiment herein. [Figure 4A] 2 illustrates a method for magnetizing one or more rare earth metals to form the rotor assembly of FIG. 1 according to one embodiment herein. [Figure 4B] 2 illustrates a method for magnetizing one or more rare earth metals to form the rotor assembly of FIG. 1 according to one embodiment herein. DETAILED DESCRIPTION OF THE INVENTION

[0023] In the following description, for purposes of explanation, numerous 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. Some features described below can be used independently of each other or in any combination with other features. Individual features may not address all of the above-mentioned problems, or may only address some of the above-mentioned problems. Some of the above-mentioned problems may not be completely addressed by any of the features described herein.

[0024] The following description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the present disclosure. Rather, the ensuing description of exemplary embodiments will provide those skilled in the art with an enabling description for implementing the exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the spirit and scope of the present disclosure as defined.

[0025] As used herein, the words "exemplary" and / or "demonstrative" mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. Additionally, any aspect or design described herein as "exemplary" and / or "demonstrative" is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to exclude equivalent exemplary structures and techniques known to those skilled in the art. Furthermore, to the extent that the terms "including," "having," "containing," and other similar terms are used in either the detailed description or the claims, such terms are intended to be inclusive, without excluding any additional or other elements, in a manner similar to the open transitional term "comprising."

[0026] Throughout this specification, references to "one embodiment" or "an embodiment" or "one example" or "an example" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrase "in one embodiment" or "in an embodiment" in various places throughout this specification do not necessarily all refer to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0027] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that as used herein, the terms "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude 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.

[0028] The accompanying drawings are used to facilitate understanding of various technical features, and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. Therefore, the present disclosure should be interpreted as covering any modifications, equivalents, and alternatives in addition to those specifically described in the accompanying drawings. Although terms such as "first," "second," etc. may be used in this specification to describe various elements, these elements should not be limited by these terms. These terms are generally used only to distinguish one element from another.

[0029] Accordingly, embodiments herein disclose a system for constructing a rotor assembly by magnetizing one or more rare earth metals. The system includes one or more laminate sheets. The one or more laminate sheets are stacked together to construct a laminate block. The one or more laminate blocks are stacked to construct the 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 mechanically configured to provide a predetermined space for disposing the one or more rare earth metals in an unmagnetized state.

[0030] The system includes a magnetizing unit including one or more magnetizing surfaces and one or more magnetizing windings configured to magnetize one or more rare earth metals of the rotor assembly by passing a predetermined supply through the one or more magnetizing windings.

[0031] Referring now to the drawings, and more particularly to FIGS. 1-4, in which like reference characters indicate corresponding features consistently throughout the views, there is shown a preferred embodiment.

[0032] FIG. 1A illustrates a system 101 for magnetizing one or more rare earth metals 110 to construct a rotor assembly 100, according to one embodiment of the present disclosure. The system 101 includes one or more lamination sheets 114. The one or more lamination sheets 114 are stacked together using one or more connecting means. Each of the one or more lamination sheets 114 includes one or more connecting means. The one or more connecting means are configured to stack the one or more lamination sheets 114 together. The one or more lamination sheets 114 are stacked together to construct a lamination block 116. The one or more lamination blocks 116 are stacked to construct the rotor assembly 100.

[0033] The rotor assembly 100 includes one or more slots 102, one or more weight-reducing cutouts 104, one or more balancing rings 106, and a shaft slot 108. The one or more slots 102 are mechanically configured to provide a predetermined space for disposing one or more unmagnetized rare earth metals 110. In one embodiment, the one or more slots 102 can vary in number and size based on the power requirements of the electric machine. In one embodiment, the electric machine includes, but is not limited to, a mid-drive electric machine and a hub electric machine. In another embodiment, the electric machine includes, but is not limited to, an interior permanent magnet (IPM) electric machine and a surface permanent magnet (SPM) electric machine.

[0034] The one or more weight-reducing cutouts 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-reducing cutouts 104 may be on the axial and longitudinal surfaces of the rotor assembly 100. The one or more rare earth metals 110 may be inserted into one or more slots 102 in one or more stacked blocks 116. In yet another embodiment, the shape of the one or more rare earth metals 110 may include, but is not limited to, a slab, a rod, or a cylinder. In yet another embodiment, the one or more rare earth metals 110 may be in a solid or liquid state. The rotor assembly 100 includes one or more surfaces 118 on an outer periphery 120 of the rotor assembly 100. The one or more surfaces 118 include a first predetermined shape.

[0035] Additionally, system 101 includes a magnetizing unit 122. Magnetizing unit 122 includes one or more magnetizing surfaces 124 and one or more magnetizing windings 126. One or more magnetizing surfaces 124 are configured to magnetize one or more rare earth metals 110 of rotor assembly 100 by passing a predetermined supply through one or more magnetizing windings 126. In one embodiment, the predetermined supply may vary based on the type of one or more rare earth metals. In yet another embodiment, the type of one or more rare earth metals may vary based on the application.

[0036] The predetermined feeding amount can vary based on demand. In one embodiment, the magnetizing unit 122 is configured to control the predetermined feeding using one or more sensing means. One or more magnetizing surfaces 124 of the magnetizing unit 122 include a second predetermined shape. The first predetermined shape and the second predetermined shape are configured to be aligned with each other to avoid incorrect positioning of the rotor assembly 100 by the magnetizing unit 122.

[0037] The one or more surfaces 118 of the rotor assembly 100 are positioned a predetermined distance from the one or more magnetized surfaces 124 of the magnetizing unit 122. In one embodiment, the predetermined distance can vary based on the positioning of the outer periphery 120 of the rotor assembly 100, the first predetermined shape of the one or more surfaces 118, the second predetermined shape of the one or more magnetized surfaces 124, and the orientation of the one or more rare earth metals 110.

[0038] The one or more magnetizing windings 126 include different polarities. In one embodiment, the different polarities of the one or more magnetizing windings 126 include positive and negative polarities. The one or more magnetizing windings 126 with different polarities are configured to magnetize the one or more rare earth metals 110 such that one or more adjacent magnetic poles of the rotor assembly 100 are opposite (NS, SN).

[0039] Additionally, the magnetizing unit 122 includes one or more magnetic flux concentrators 128. The one or more magnetic flux concentrators 128 are configured to separate the one or more north (N) magnetized surfaces 124 from the one or more south (S) magnetized surfaces 124. The one or more magnetized surfaces 124 of the rotor assembly 100, the one or more magnetic flux concentrators 128, and the one or more magnetized surfaces 124 of the magnetizing unit 122 are configured to focus magnetic flux lines from the magnetizing unit 122 to the one or more rare earth metals 110 disposed on the one or more slots 102 of the rotor assembly 100. In one embodiment, the one or more magnetic flux concentrators 128 are comprised 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 magnetic flux concentrators 128 may be air.

[0040] The one or more rare earth metals 110 are bonded to the one or more stacking blocks 116 using an adhesive. In one embodiment, the one or more rare earth metals 110 are clamped to the one or more stacking blocks 116 using one or more clamps. In one embodiment, an adhesive is applied to the one or more rare earth metals 110 before they are inserted into the one or more slots 102. The one or more stacking blocks 116 are joined with the aid of one or more balancing rings 106 using one or more joining processes. In one embodiment, the one or more joining processes may include, but are not limited to, riveting, welding, clamping, interlocking, gluing, and fastening.

[0041] The rotor shaft is positioned in the shaft slot 108. In one embodiment, the rotor shaft is positioned in the shaft slot 108 using one or more assembly techniques. In one embodiment, the one or more assembly techniques may include, but are not limited to, a press-fit process. As used herein, a press-fit process is an assembly in which one part is tightly inserted into a hole in another part. The inserted part is typically larger than the mating hole. The assembly remains in place due to friction and the force of the two parts pressing against each other.

[0042] The rotor assembly 100 is further disposed in a magnetizing unit 122 to magnetize the one or more rare earth metals 110. The magnetizing unit 122 further includes a cooling unit 130 and an insulating unit 132. The cooling unit 130 is configured to dissipate thermal energy generated in the one or more magnetizing windings 126 while supplying a predetermined power to the one or more rare earth metals 110. The insulating unit 132 is configured to prevent magnetic flux (generated during magnetization) from scattering outside the magnetizing unit 122. In one embodiment, the one or more magnetizing windings 126 with different polarities are configured to magnetize the one or more rare earth metals 110 at a time such that one or more adjacent magnetic poles of the rotor assembly 100 are opposite (NS, SN). The rotor assembly 100 with the one or more magnetized rare earth metals 110 is disposed in a stator to form an electric machine.

[0043] 1B is a top view of a rotor assembly 100 with a magnetizing unit 122 according to one embodiment of the present disclosure. The magnetizing unit 122 includes one or more magnetizing surfaces 124 and one or more magnetizing windings 126. The one or more magnetizing surfaces 124 are configured to magnetize one or more rare earth metals 110 of the rotor assembly 100 by passing a predetermined supply through the one or more magnetizing windings 126. In one embodiment, the predetermined supply may vary based on the type of the one or more rare earth metals. In yet another embodiment, the type of the one or more rare earth metals may vary based on the application.

[0044] The predetermined feed rate may vary based on demand. In one embodiment, the magnetizing unit 122 is configured to control the predetermined feed rate using one or more sensing means. The rotor assembly 100 includes one or more surfaces 118 on an outer periphery 120 of the rotor assembly 100. The one or more surfaces 118 include a first predetermined shape.

[0045] One or more magnetizing surfaces 124 of the magnetizing unit 122 include a second predetermined shape. The first predetermined shape and the second predetermined shape are constructed to be aligned with each other to avoid misalignment of the rotor assembly 100 and the magnetizing unit 122.

[0046] The one or more surfaces 118 of the rotor assembly 100 are positioned a predetermined distance from the one or more magnetized surfaces 124 of the magnetizing 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 magnetized surfaces 124, and the orientation of the one or more rare earth metals 110.

[0047] The one or more magnetizing windings 126 include different polarities. In one embodiment, the different polarities of the one or more magnetizing windings 126 include positive and negative polarities. The one or more magnetizing windings 126 with different polarities are configured to magnetize the one or more rare earth metals 110 such that one or more adjacent magnetic poles of the rotor assembly 100 are opposite (NS, SN).

[0048] Additionally, the magnetizing unit 122 includes one or more magnetic flux concentrators 128. The one or more magnetic flux concentrators 128 are configured to separate the one or more north (N) magnetized surfaces 124 from the one or more south (S) magnetized surfaces 124. The one or more magnetized surfaces 124 of the rotor assembly 100, the one or more magnetic flux concentrators 128, and the one or more magnetized surfaces 124 of the magnetizing unit 122 are configured to focus magnetic flux lines from the magnetizing unit 122 to the one or more rare earth metals 110 disposed on the one or more slots 102 of the rotor assembly 100. In one embodiment, the one or more magnetic flux concentrators 128 are comprised 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 magnetic flux concentrators 128 may be air. The rotor assembly 100 is placed in a magnetizing unit 122 to magnetize the one or more rare earth metals 110 .

[0049] 1C is a partial schematic cross-sectional view of a rotor assembly 100 including a magnetizing unit 122 according to one embodiment of the present disclosure. The magnetizing unit 122 includes one or more magnetizing surfaces 124 and one or more magnetizing windings 126. The one or more magnetizing surfaces 124 are configured to magnetize one or more rare earth metals 110 of the rotor assembly 100 by passing a predetermined supply through the one or more magnetizing windings 126. In one embodiment, the predetermined supply may vary based on the type of the one or more rare earth metals. In yet another embodiment, the type of the one or more rare earth metals may vary based on the application.

[0050] The predetermined feeding amount can vary based on demand. In one embodiment, the magnetizing unit 122 is configured to control the predetermined feeding using one or more sensing means. One or more magnetizing surfaces 124 of the magnetizing unit 122 include a second predetermined shape. The first predetermined shape and the second predetermined shape are configured to be aligned with each other to avoid incorrect positioning of the rotor assembly 100 by the magnetizing unit 122.

[0051] The one or more surfaces 118 of the rotor assembly 100 are positioned a predetermined distance from the one or more magnetized surfaces 124 of the magnetizing 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, the second predetermined shape of the one or more magnetized surfaces 124, and the orientation of the one or more rare earth metals 110.

[0052] Additionally, the magnetizing unit 122 includes one or more magnetic flux concentrators 128. The one or more magnetic flux concentrators 128 are configured to separate the one or more north (N) magnetized surfaces 124 from the one or more south (S) magnetized surfaces 124. The one or more magnetized surfaces 124 of the rotor assembly 100, the one or more magnetic flux concentrators 128, and the one or more magnetized surfaces 124 of the magnetizing unit 122 are configured to focus magnetic flux lines from the magnetizing unit 122 to the one or more rare earth metals 110 disposed on the one or more slots 102 of the rotor assembly 100. In one embodiment, the one or more magnetic flux concentrators 128 are comprised 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 magnetic flux concentrators 128 may be air.

[0053] 2A shows a top view of one or more laminate sheets 114 of a rotor assembly 100 according to embodiments herein. The system 101 includes one or more laminate sheets 114. The one or more laminate sheets 114 are laminated together to build a laminate block 116. The one or more laminate blocks 116 are laminated together to build the rotor assembly 100.

[0054] 2B is an isometric view of a stacked block 116 of a rotor assembly 100 according to one embodiment of the present disclosure. The stacked block 116 of the rotor assembly 100 includes one or more slots 102. The one or more slots 102 are mechanically configured to provide a predetermined space for placing one or more rare earth metals in an unmagnetized state. The one or more rare earth metals 110 are magnetized using a magnetizing unit 122. The pole adjacent to the north pole (N) becomes the south pole (S).

[0055] 2C shows an isometric view of one or more stacked blocks 116 of a rotor assembly 100 according to one embodiment of the present disclosure. The one or more stacked blocks 116 are stacked together to form the rotor assembly 100. The one or more stacked blocks 116 are arranged and magnetized such that the same poles (NN, SS) are aligned along the longitudinal axis. The one or more balancing rings 106 are configured to position the one or more stacked blocks 116 together with the aid of one or more joining processes. In one embodiment, the one or more joining processes may include, but are not limited to, riveting, welding, clamping, interlocking, gluing, and fastening processes.

[0056] One or more magnets are longitudinally arranged with the same polarity (NN, SS) within the plurality of magnetic slots with the aid of an adhesive. In one embodiment, the one or more rare earth metals 110 are clamped to one or more stacked blocks 116 using one or more clamps.

[0057] FIG. 3 is an exploded view of an electric machine 300 of a system 101 according to an embodiment herein. The electric machine 300 of FIG. 3 shows a rotor assembly 100 having a stator 304. The rotor shaft 302 of the rotor assembly 100 is positioned within the shaft slot 108. In one embodiment, the rotor shaft 302 of the rotor assembly 100 is positioned within the shaft slot 108 using a press-fit process. As used herein, a press-fit process is an assembly in which one part is tightly inserted into a hole in another part. The inserted part is typically larger than the mating hole. The assembly remains in place due to friction and the force of the two parts pressing against each other. Additionally, FIG. 3 explicitly illustrates the placement / assembly of the rotor assembly 100 with one or more magnetized rare earth metals onto the stator 304 to form the electric machine.

[0058] 4A and 4B illustrate a method 400 for magnetizing one or more rare earth metals 110 to construct the rotor assembly 100 of FIG. 1 according to one embodiment of the present disclosure. In step 402, one or more laminate sheets 114 are stacked together to construct a laminate block 116. Each of the one or more laminate sheets 114 includes one or more connecting means. The one or more connecting means are configured to stack the one or more laminate sheets 114 together.

[0059] In step 404, one or more rare earth metals 110 are positioned in one or more slots 102. In step 406, the one or more rare earth metals 110 are adhered to the one or more slots 102. In one embodiment, an adhesive is applied to the one or more rare earth metals 110 before they are inserted into the one or more slots 102. In one embodiment, the one or more rare earth metals 110 are clamped to one or more stacking blocks 116 using one or more clamps.

[0060] In step 408, one or more lamination blocks 116 are stacked in the presence of the rotor shaft 302 using one or more joining processes to construct a rotor assembly 100 having one or more balancing rings 106. The rotor assembly 100 includes one or more surfaces 118 on an 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, an adhesive process, and a fastening process.

[0061] In step 410, the rotor assembly 100 is balanced. One or more balancing rings 106 are configured to hold one or more stacked blocks 116 together with the aid of one or more joining processes. In one embodiment, the one or more joining processes may include, but are not limited to, riveting, welding, clamping, interlocking, gluing, and fastening processes.

[0062] In step 412, the rotor assembly 100 is placed in the magnetizing unit 122. The magnetizing unit 122 includes one or more magnetizing surfaces 124 and one or more magnetizing windings 126. The one or more magnetizing surfaces 124 of the magnetizing unit 122 are formed in a second predetermined shape.

[0063] In step 414, the first predetermined shape and the second predetermined shape are aligned together in a manner that avoids misalignment of the rotor assembly 100 and the magnetizing unit 122.

[0064] In step 416, one or more surfaces 118 of rotor assembly 100 are positioned a predetermined distance from one or more magnetizing surfaces 124 of magnetizing unit 122. In one embodiment, the predetermined distance varies based on the circumference of 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 magnetizing surfaces 124, and the orientation of the one or more rare earth metals 110. In another embodiment, magnetizing unit 122 further includes one or more magnetic flux concentrators 128.

[0065] In step 418, magnetic flux lines are focused from the magnetizing unit 122 to the one or more rare earth metals 110 using one or more surfaces 118 of the rotor assembly 100, one or more magnetic flux concentrators 128, and one or more magnetizing surfaces 124 of the magnetizing unit 122. In one embodiment, the one or more magnetizing windings 126 include different polarities. In step 420, the one or more rare earth metals 110 are magnetized using the one or more magnetizing windings 126 by passing a predetermined supply through the one or more magnetizing windings 126. The one or more magnetizing windings 126 include different polarities. The different polarities include positive and negative polarities. The method 400 further includes magnetizing the one or more rare earth metals 110 using the one or more magnetizing windings 126 having different polarities such that one or more adjacent magnetic poles of the rotor assembly 100 are opposite (NS, SN).

[0066] The method 400 further includes separating one or more north pole (N) magnetized surfaces 124 from one or more south pole (S) magnetized surfaces 124 using one or more magnetic flux concentrators 128. The method 400 further includes uniformly magnetizing one or more rare earth metals 110 of the rotor assembly 100 at a time using the magnetizing unit 122 such that one or more adjacent magnetic poles of the rotor assembly 100 are opposite (NS, SN).

[0067] Proposed System 101 The proposed system does not require skilled personnel to insert the magnets to ensure alternating poles. 101 does not require any additional mechanism to identify the alternating poles. . stem 101 eliminates positioning of magnets with the wrong polarity, which can lead to rotor assembly 100 failure and result in rotor assembly 100 rejection and internal process defect costs. , Shi stem 101 facilitates packaging, storage, and transportation of multiple rare earth metals 110 when comparing magnetized magnets. . stem 101 The magnets facilitate easy handling from the electric machine assembly line to the magnetization station. The magnet coating material experiences little or no wear, improving corrosion and wear resistance. The proposed system reduces overall assembly time due to the ease of handling of unmagnetized magnets. The proposed system facilitates the assembly of one or more balancing rings 106, one or more joining processes, rotor shafts, and balancing stations. The one or more rare earth metals 110 eliminate attractive forces between the core and magnet, making adhesive application easy and uniform. The one or more rare earth metals 110 minimize repulsive forces acting between the evenly divided stacks, aiding in one or more joining processes. Furthermore, there is no or minimal gap between the evenly divided stacks. The proposed system ensures and improves worker safety during material handling of the one or more rare earth metals 110 compared to magnetized magnets.

[0068] S stem 101 provides a solution to alleviate problems caused by heat generated by the rotation of an electric machine by repeating the magnetization process. , Shi stem 101 provides a solution to the problem encountered during the co-positioning of like poles (NN or SS) of magnets on the longitudinal axis of the rotor assembly 100 by inserting one or more rare earth metals 110 in an unmagnetized state into one or more slots 102 of the rotor assembly 100. , Shi stem 101ensures equal Tesla values ​​of one or more magnetized rare earth metals by single-shot magnetization to avoid uneven polarization, wear problems, voltage harmonics, and low efficiency. , Shi stem 101 controls the vibration problem by avoiding torque fluctuations in the rotor assembly 100. The torque fluctuations are reduced by single shot magnetization.

[0069] In addition , Shi stem 101 reduces voltage harmonics in an electric machine by providing one or more surfaces 118 on the outer periphery 120 of the rotor assembly 100 instead of a circular rotor. Each of the one or more rare earth metals 110 is supplied with a predetermined amount of rare earth metal using one or more magnetizing windings 126 of a magnetizing unit 122. The one or more magnetizing windings 126 include different polarities that magnetize adjacent poles of the rotor assembly 100 in opposite directions (NS, SN). . stem 101 reduces eddy current losses in the electric machine by constructing the rotor assembly 100 as a multi-component assembly.

[0070] moreover , Shi stem 101 provides an approach to magnetizing one or more rare earth metals 110 at an efficient Tesla value. The Tesla value of the one or more magnetized rare earth metals can be varied based on the type of the one or more rare earth metals 110 and a predetermined supply from one or more magnetizing windings 126 of the magnetizing unit 122.

[0071] The foregoing description of specific embodiments fully reveals the general nature of the embodiments herein, and others, by applying current knowledge, may easily modify and / or adapt such specific embodiments for various uses without departing from the general concept; therefore, such adaptations and modifications should, and are intended to, be understood within the meaning and range of equivalents of the disclosed embodiments. It should be understood that the phraseology or terminology employed herein is for purposes of description and not of limitation. Thus, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims. Improvements and modifications may be incorporated herein without departing from the scope of the invention. [Explanation of symbols]

[0072] 101 System 100 Rotor Assembly 102 One or more slots 104 One or more weight-reducing cutouts 106 One or more balancing rings 108 shaft slot 110 One or more rare earth metals 114 One or more laminated sheets 116 stacked block or one or more stacked blocks 118 One or more faces 120 perimeter 122 Magnetizing unit 124 One or more magnetized surfaces 126 One or more magnetized windings 128 One or more magnetic flux concentrators 130 Cooling Unit 132 Insulation Unit 302 rotor shaft 304 Stator

Claims

1. A system (101) for magnetizing one or more rare earth metals (110) to form a rotor assembly (100), comprising: stacking one or more laminate sheets (114) to form a laminate block (116); one or more stacked blocks (116) are stacked to construct the rotor assembly (100), the rotor assembly (100) having one or more surfaces (118) on an outer periphery (120) of the rotor assembly (100); The rotor assembly (100) comprises one or more slots (102) mechanically configured to provide a predetermined space for placement of one or more unmagnetized rare earth metals (110); The magnetizing unit (122) comprises one or more magnetizing surfaces (124) and one or more magnetizing windings (126), the one or more magnetizing surfaces (124) being configured to magnetize the one or more rare earth metals (110) of the rotor assembly (100) by passing a predetermined supply through the one or more magnetizing windings (126).

2. 2. The system of claim 1, wherein the one or more magnetizing windings (126) include different polarities, and the one or more magnetizing windings (126) including different polarities are configured to magnetize the one or more rare earth metals (110) in a manner where one or more adjacent magnetic poles of the rotor assembly (100) are opposite (North-South, South-North).

3. 2. The system of claim 1, wherein the one or more surfaces (118) of the rotor assembly (100) comprise a first predetermined shape and the one or more magnetized surfaces (124) of the magnetizing unit (122) comprise a second predetermined shape.

4. 4. The system of claim 3, wherein the first predetermined shape and the second predetermined shape are configured to be positioned relative to one another to avoid mispositioning of the rotor assembly (100) with the magnetizing unit (122).

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

6. 6. The system of 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 (118) of the one or more surfaces and the second predetermined shape of the one or more magnetized surfaces (124), and the orientation of the one or more rare earth metals (110).

7. 2. The system of claim 1, wherein the magnetizing unit further comprises one or more magnetic flux concentrators configured to separate the one or more magnetized surfaces of a north pole (N) from the one or more magnetized surfaces of a south pole (S), and the one or more surfaces of the rotor assembly (100), the one or more magnetic flux concentrators, and the one or more magnetized surfaces of the magnetizing unit (122) are configured to focus magnetic flux lines from the magnetizing unit (122) to the one or more rare earth metals (110) disposed on the one or more slots of the rotor assembly (100).

8. 2. The system of claim 1, wherein the magnetizing unit is configured to uniformly magnetize the one or more rare earth metals of the rotor assembly at one time in an opposite manner (North-South, South-North) of one or more adjacent magnetic poles of the rotor assembly.

9. A method (400) for magnetizing one or more rare earth metals (110) to construct a rotor assembly (100), comprising: stacking one or more laminate sheets (114) to form a laminate block (116); disposing one or more rare earth metals (110) in one or more slots (102); Adhering one or more rare earth metals (110) to the one or more slots (102); stacking one or more stacked blocks (116) in the presence of a rotor shaft 302 using one or more joining processes to build a rotor assembly (100) with one or more balancing rings (106); balancing the rotor assembly (100), the rotor assembly (100) having one or more surfaces (118) on an outer periphery (120), the one or more surfaces (118) of the rotor assembly (100) having a first predetermined shape; placing the rotor assembly (100) on a magnetizing unit (122), the magnetizing unit (122) having one or more magnetizing surfaces (124) and one or more magnetizing windings (126), the one or more magnetizing surfaces (124) of the magnetizing unit (122) having a second predetermined shape; and positioning the rotor assembly (100) and the magnetizing unit (122) together in a manner that avoids misalignment of the rotor assembly (100) and the magnetizing unit (122) in correspondence with the second predetermined shape; 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 magnetizing unit (122), the predetermined distance varying 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 magnetized surfaces (124), and the orientation of the one or more rare earth metals (110); concentrating magnetic flux lines from the magnetizing unit (122) to the one or more rare earth metals (110) using the one or more surfaces (118) of the rotor assembly (100), one or more magnetic flux concentrators (128), and the one or more magnetizing surfaces (124) of the magnetizing unit (122), the magnetizing unit (122) further comprising the one or more magnetic flux concentrators (128); magnetizing one or more rare earth metals (110) by passing a predetermined supply through one or more magnetizing windings (126), wherein the one or more magnetizing windings (126) are of different polarities; A method comprising:

10. 11. The method of claim 10, further comprising magnetizing one or more rare earth metals in an opposite (N-S, S-N) manner with one or more magnetizing windings having different polarities, the one or more adjacent magnetic poles of the rotor assembly being opposite (N-S, S-N).

11. 11. The method (400) of claim 10, further comprising using the one or more magnetic flux concentrators (128) to separate the one or more magnetized surfaces (124) of a north pole (N) from the one or more magnetized surfaces (124) of a south pole (N).

12. 11. The method of claim 10, further comprising using the magnetizing unit to uniformly magnetize the one or more rare earth metals of the rotor assembly in an opposite (North-South, South-North) manner at one time.

13. 11. The method (400) of claim 10, wherein the one or more joining processes comprise riveting, welding, clamping, interlocking, gluing, and fastening processes.

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