Brushless DC Motor with Integrated Rotor Gear and Asymmetric Magnet Arrangement
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Solution Overview
Problem
Brushless DC motors face challenges in starting from 'dead orientations', are cumbersome and heavy due to toothed rings, and lack energy management capabilities, such as recharging batteries with excess energy.
Innovation Solution
The design includes a rotor with permanent magnets arranged in a ring-like manner, a bearing assembly with integrated toothed rings to reduce volume and weight, and starter solenoids for initiating rotation and capturing energy, which can be used to charge batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a toothed ring is positioned below the magnets-spacers structure, then the motor can transfer rotation to the axle, but the overall volume and weight of the motor increase
Solution Approach 1:
The patent combines the toothed ring with the rotor structure by integrating it into the rotor body or rotor support ring, eliminating the need for a separate toothed ring component. This merging reduces the overall number of parts, decreases weight, and simplifies the structure while maintaining the power transmission function from the rotor to the axle.
2Ease of manufacture
If the cavity in the solenoid is made larger to accommodate the toothed ring, then the toothed ring can pass through, but the overall motor volume increases
Solution Approach 1:
By integrating the toothed ring into the rotor structure rather than making it a separate component that must pass through the solenoid cavity, the patent eliminates the need for enlarged cavities. The merged structure allows the toothed ring to rotate with the rotor without requiring additional space in the solenoid assembly, thereby reducing overall motor volume.
3Ease of operation
If the motor is started when permanent magnets are aligned at the middle line of solenoids (dead orientation), then the motor can start, but an additional mechanism is required increasing complexity
Solution Approach 1:
The patent introduces asymmetry in the magnetic field configuration by positioning the permanent magnets at offset angles rather than symmetrically aligned with the solenoids. This asymmetric arrangement ensures that there is always a non-zero magnetic field interaction between the magnets and solenoids, eliminating the dead orientation problem and enabling direct starting without additional mechanisms.
4Force
If spacers of high permeability material are positioned between adjacent permanent magnets, then the magnetic field density increases, but the structure becomes more complex and heavier
Solution Approach 1:
The patent changes the geometric parameters of the permanent magnets themselves, specifically designing them with tapered or angled surfaces that naturally concentrate and direct the magnetic field lines. This parameter change in magnet geometry achieves high magnetic field density without requiring additional high permeability spacers, thereby reducing material quantity and structural complexity.
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 motor can start from dead orientations, has reduced volume and weight, and can manage energy by charging batteries using excess energy, enhancing efficiency and functionality.
Implementation Method 1
The electromagnetic interaction between the rotor and the stator provide the forces that turn the shaft and operate on the load
Implementation Method 2
The bearing assembly comprises an inner and outer ring with one or more bearings disposed therebetween
Data Source
AI summary
A motor apparatus having a rotor that includes one or more permanent magnets disposed in ring-like manner, wherein similar poles of adjacent magnets face one another, and further wherein a gear mechanism (e.g., a toothed ring) is configured to transfer rotation from the rotor to an external gear mechanism. The motor may also include a stator comprising one or more solenoids and a bearing assembly that includes a rotating bearing element integrated with a toothed element for engaging with a gear and axle assembly. The rotating bearing element and integrated toothed gear element may pass through cavities of the main solenoids and provide for minimal cavity size, improving motor efficiencies.