Annular Magnetic Pole Member for Gear Assembly
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Solution Overview
Problem
The existing magnetic gear devices require complex and mechanically firm structures to maintain minute gaps between magnetic pole pieces, leading to poor assemblability, especially for larger sizes.
Innovation Solution
An annular magnetic pole member with a simpler structure is designed, using a cylindrical low-speed rotor with laminated steel sheets and fastening bolts to maintain the magnetic pole array, allowing for easier assembly and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex mechanically firm structure is used to maintain the minute gap between magnetic pole pieces, then the gap stability is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The annular magnetic pole member is divided into multiple independent magnetic pole pieces that are arranged around the circumference. Each magnetic pole piece is separated by non-magnetic material, creating individual units that can be manufactured and assembled separately. This segmentation reduces the overall structural complexity while maintaining the required gap stability through precise positioning of discrete elements rather than requiring a complex continuous support structure.
Solution Approach 2:
Non-magnetic material is introduced as an intermediary element between adjacent magnetic pole pieces. This non-magnetic material serves multiple functions: it maintains the minute gap between magnetic pole pieces, provides mechanical support, and prevents magnetic flux leakage. By using this intermediary material, the patent achieves gap stability without requiring complex mechanical fastening structures.
2Reliability
If a complex holding structure is used to maintain the minute gap, then the gap maintenance is improved, but the assemblability deteriorates
Solution Approach 1:
The magnetic pole member is segmented into multiple pole pieces that can be manufactured separately using standard machining processes. Each pole piece is a simple component that can be easily fabricated, and the segmented design allows for modular assembly. This segmentation transforms a complex continuous structure into simple discrete components that are much easier to manufacture and assemble.
Solution Approach 2:
The non-magnetic material acts as a mediator that simplifies the assembly process. It provides a built-in spacing mechanism that automatically maintains the required gap during assembly, eliminating the need for complex adjustment mechanisms or precision alignment procedures. This intermediary element makes the assembly process more straightforward and improves overall assemblability.
3Strength
If a complex structure is used for larger-sized modulation magnetic poles, then the structural integrity is improved, but the manufacturing difficulty increases
Solution Approach 1:
For larger-sized magnetic pole members, the segmentation into multiple pole pieces becomes even more advantageous. Each individual pole piece can be manufactured using standard machining processes without requiring complex tooling or specialized equipment. The modular segmented design allows for easier quality control and simpler manufacturing workflows compared to attempting to machine a single large complex structure.
Solution Approach 2:
Multiple simple pole pieces are merged together to form the complete annular magnetic pole member. This combining approach allows the final assembly to achieve the required structural integrity and size while each individual component remains simple to manufacture. The non-magnetic material between pieces provides both mechanical support and magnetic flux management, enabling the construction of large-sized members without proportionally increasing manufacturing difficulty.
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
The annular magnetic pole member provides improved assemblability and manufacturing ease, maintaining magnetic performance comparable to existing devices while simplifying the structure, particularly for larger sizes.
Implementation Method 1
a modulation magnetic pole including a plurality of magnetic pole pieces between a first permanent magnet field and a second permanent magnet field and modulates magnetic fields of the first permanent magnet field and the second permanent magnet field
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
There are provided a core portion (2a) including a plurality of single layer units (U) laminated in a direction of a center axis (R), each of the single layer units (U) including a plurality of magnetic body pieces (2f) annularly arranged around the center axis (R) in a state where the magnetic body pieces (2f) are in contact with each other, and each of the magnetic body pieces (2f) including a plurality of openings (2g); and a plurality of fastening bolts (2b) that are respectively inserted through a plurality of penetration holes (2e) which are the plurality of openings (2g) continuously connected to each other in the direction of the center axis (R). In the single layer units (U) adjacent to each other, contact positions of the magnetic body pieces (2f) are different from each other.