Axial-Flow Machine Dimensionally Stable Rotor Assembly
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Solution Overview
Problem
Existing axial-flow machines require large dimensions for spoked wheels to withstand centrifugal forces, limiting the size of permanent magnets and motor power, necessitating the use of expensive rare-earth magnets to compensate, thereby increasing manufacturing costs.
Innovation Solution
The use of adhesive joints to secure permanent magnets on the rotor hub and bracing means on the outer circumference, eliminating the need for interlocking connections, allowing for a compact rotor design with high magnetic volume fraction and stability, while a flexible adhesive and soft-magnetic covers reduce mechanical and thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an interlocking connection is used to secure permanent magnets on the rotor, then mechanical strength is improved, but the rotor dimensions become larger and magnetic volume fraction is reduced
Solution Approach 1:
The patent replaces the mechanical interlocking connection system with an adhesive bonding system. The adhesive joints secure the permanent magnets to the rotor hub and connect adjacent magnets without requiring mechanical interlocking structures, thereby eliminating the volume occupied by such structures and increasing the magnetic volume fraction while maintaining mechanical strength through chemical bonding.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical interlocking to adhesive bonding, fundamentally altering how permanent magnets are secured on the rotor. This parameter change allows for a more compact design where magnets can be positioned closer together and secured with minimal structural overhead, maximizing the magnetic volume fraction.
2Ease of manufacture
If adhesive joints are used to secure permanent magnets, then manufacturing cost is reduced and magnetic volume fraction is increased, but mechanical load capability may be reduced
Solution Approach 1:
The patent substitutes mechanical interlocking with adhesive bonding, eliminating the need for complex mechanical structures and reducing manufacturing costs. The adhesive joints provide sufficient mechanical load capability for rotor operation while allowing for simpler, more cost-effective manufacturing processes and enabling higher magnetic volume fraction.
Solution Approach 2:
The patent employs adhesive materials that create a composite structure between the permanent magnets and rotor hub. This composite bonding approach combines the strengths of different materials to achieve both cost-effectiveness and adequate mechanical load capability, while the absence of mechanical interlocking structures maximizes the magnetic volume fraction.
3Volume of moving object
If the rotor is designed with compact dimensions, then magnetic volume fraction is increased, but dimensional stability under centrifugal force may be compromised
Solution Approach 1:
The patent replaces mechanical interlocking structures with adhesive bonding, enabling a more compact rotor design. The adhesive joints distribute stresses uniformly across the magnet-rotor interface, maintaining dimensional stability under centrifugal forces while allowing for reduced overall rotor dimensions and increased magnetic volume fraction.
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 design achieves high motor power and stability with reduced manufacturing costs by using ferrite or rare-earth magnets, minimizing the risk of adhesive failure, and reducing eddy-current losses, while maintaining dimensional stability and thermal resistance.
Implementation Method 1
permanent magnets seated on the rotor hub via first adhesive joints (10.1) equipped with adhesive (9), and adjoin one another via second adhesive joints (10.2) equipped with adhesive
Implementation Method 2
a bracing means (8), which is disposed on the outer circumference of the rotor and encircles it in closed manner and which urges the permanent magnets with a radial tension force, in order to withstand at least the centrifugal forces
Implementation Method 3
bracing means which urges the permanent magnets with a radial tension force
Implementation Method 4
permanent magnets (7.1, 7.2), which are disposed circularly around the machine shaft (3) and which are alternately magnetized... stators (4, 5) disposed on both sides of the rotor (2)... the adhesive is prevented from flowing due to the radial and axial dimensional stability of the rotor
Data Source
AI summary
An axial-flow machine has a dimensionally stable assembly, a machine shaft, a rotor fastened on the machine shaft and provided with a rotor hub, permanent magnets disposed circularly around the machine shaft, an adhesive and a brace, which is disposed on the outer circumference of the rotor and encircles it in closed manner and which urges the permanent magnets with a radially inwardly directed tension force, and stators disposed on both sides of the rotor. The permanent magnets are seated on the rotor hub via first adhesive joints equipped with adhesive and adjoin one another via second adhesive joints equipped with adhesive, wherein the permanent magnets, the rotor hub, the brace and the adhesive form the dimensionally stable assembly, the radial and axial dimensional stability of which is determined substantially by the radial tension force of the brace on the permanent magnets.