Angled Magnetic Motor Modules Eliminating Back-Iron
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Solution Overview
Problem
Conventional linear and rotary motors face inefficiencies due to high core losses, increased material consumption, and limited applications resulting from the use of back-iron in magnetic flux return paths, which also lead to instability and higher manufacturing costs.
Innovation Solution
The implementation of motor modules with angled magnetic surfaces and field pole members that form straight or angled flux paths, eliminating the need for back-iron and reducing magnetic reluctance, thereby enhancing efficiency and torque or force output per unit volume and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If magnetic poles are positioned at larger radial distances from the rotor shaft to increase torque arm distance, then output torque increases, but motor volume increases and material consumption increases
Solution Approach 1:
The patent transitions from conventional radial magnetic pole arrangement to axial magnetic pole arrangement. Instead of positioning magnetic poles radially outward from the rotor shaft to increase torque arm distance, the invention positions magnetic poles axially on the rotor surface, creating flux paths that traverse the rotor axially. This dimensional change allows torque generation without increasing the radial distance between magnetic poles and shaft, thereby maintaining compact motor volume while achieving the desired torque output.
2Reliability
If back-iron is added to complete magnetic flux return paths, then magnetic circuit is completed, but core losses increase due to increased magnetic material volume and flux path length
Solution Approach 1:
The patent extracts and eliminates the back-iron component from the magnetic circuit design. Instead of using back-iron to complete the flux return path, the invention employs alternative magnetic circuit configurations that complete the flux path without requiring additional back-iron material. This extraction of the back-iron element directly reduces the volume of magnetic material and shortens the flux path length, thereby reducing core losses while maintaining complete magnetic flux return paths.
Solution Approach 2:
The patent changes the orientation and configuration of magnetic flux paths from conventional radial patterns requiring back-iron to axial patterns that naturally complete flux returns without back-iron. By reorienting the magnetic circuit in the axial dimension rather than relying on radial extension with back-iron, the invention completes magnetic flux paths while minimizing magnetic material volume and flux path length.
3Power
If magnetic poles are positioned at larger radial distances, then output torque increases, but hysteresis and eddy current losses increase
Solution Approach 1:
The patent reconfigures the magnetic circuit from radial flux paths to axial flux paths. This dimensional change creates shorter and more direct magnetic flux paths that traverse the rotor axially rather than radially outward to back-iron structures. The axial flux configuration reduces the length of magnetic material traversed by flux, thereby reducing hysteresis and eddy current losses while maintaining effective torque generation through optimized axial magnetic pole positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in motors with reduced size, weight, and manufacturing costs, while achieving comparable performance to traditional large motors with lower magnetic losses and increased efficiency, by eliminating back-iron and optimizing magnetic flux paths.
Implementation Method 1
The angled flux interaction surfaces and the angled magnetic surfaces define air gaps. As such, the angled flux interaction surfaces are configured to magnetically couple the field pole members to the magnets
Implementation Method 2
one or more coils can be disposed about each of the field pole members to form active field pole members for generating ampere-turn ('AT') flux
Data Source
AI summary
A motor module, method, apparatus and system for implementing linear and rotary motors, such as relatively large rotary motors, are disclosed. In one embodiment, an electrodynamic machine can include magnets having angled magnetic surfaces and regions of predetermined magnetic polarization. The magnets can include a first array and a second array of magnets arranged in a direction of motion. Also included are groups of field pole members arranged adjacent to the first array and the second array of magnets. The field pole members include angled flux interaction surfaces, which can be formed at the ends of the field pole members to confront the angled magnetic surfaces. In combination, the angled flux interaction surfaces and the angled magnetic surfaces define air gaps. As such, the angled flux interaction surfaces are configured to magnetically couple the field pole members to the magnets to form either a linear or rotary motor.