Brushless Motor Rotor Assembly for Precise Magnetic Pole Alignment
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Solution Overview
Problem
The low positioning accuracy of the rotor in brushless induction motors affects the performance of these motors, as existing technologies struggle to accurately position and assemble the rotor assembly and align the magnetic poles of the magnetic ring with those of the tile-shaped magnets.
Innovation Solution
The proposed solution involves an electric motor design that includes a stator assembly, a rotor assembly, and specific components such as a magnetic ring, tile-shaped magnets, and induction components. The rotor assembly is designed with a magnetic knitting frame, iron core, and positioning slots to ensure accurate alignment of magnetic poles, while the induction components sense the magnetic pole information to adjust the power supply accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rotor assembly methods are used, then assembly is simpler, but positioning accuracy of the rotor assembly is low
Solution Approach 1:
The rotor assembly is segmented into multiple functional components: magnetic ring, tile-shaped magnets, iron core, rotor end plates, and magnetic knitting frame. Each component has specific positioning features (slots, bosses, protrusions) that enable precise assembly. The segmentation allows independent manufacturing and precise positioning of each part, resolving the contradiction between assembly simplicity and positioning accuracy.
Solution Approach 2:
The magnetic knitting frame acts as an intermediary component that connects the magnetic ring, tile-shaped magnets, and iron core. It provides a structured framework with positioning slots and bosses that mediate the alignment between different magnetic components, achieving high positioning accuracy while maintaining manageable assembly complexity.
2Measurement precision
If rotor positioning accuracy is low, then assembly is easier, but induction components cannot sense magnetic poles accurately
Solution Approach 1:
The rotor components are pre-positioned during assembly using positioning slots, bosses, and protrusions. The magnetic ring, tile-shaped magnets, and iron core are preliminarily aligned through these mechanical features before final assembly, ensuring that the magnetic poles are correctly positioned for accurate sensing by the induction components.
Solution Approach 2:
The patent replaces traditional mechanical positioning methods with a magnetic positioning system. The magnetic knitting frame and magnetic ring create magnetic fields that automatically align the magnetic poles, substituting mechanical alignment with magnetic field-based positioning, thereby achieving high sensing accuracy without complex mechanical adjustment mechanisms.
3Reliability
If magnetic poles are not aligned, then assembly is less complex, but motor performance deteriorates
Solution Approach 1:
The rotor assembly uses asymmetric positioning features: positioning slots are arranged at specific angular positions, and positioning protrusions on the magnetic knitting frame correspond to these slots. This asymmetric arrangement ensures unique and precise alignment of magnetic poles, guaranteeing reliable motor performance through deterministic magnetic field configuration.
Solution Approach 2:
The patent employs magnetic field visualization through the magnetic knitting frame structure. The magnetic field distribution and pole alignment can be detected and verified through magnetic sensing, providing feedback on alignment quality. This allows verification of magnetic pole alignment without complex mechanical measurement tools, ensuring reliable motor performance.
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 improves the positioning accuracy of the rotor assembly, enhances the accuracy of induction components in sensing the tile-shaped magnet, and ultimately leads to better performance of the electric motor by ensuring precise alignment of magnetic poles.
Implementation Method 1
the induction components are arranged on the rear cover plate, and used for sensing the magnetic ring
Implementation Method 2
The electric motor employs energized coils (i.e. stator winding) to generate a rotating magnetic field which acts on the rotating magnetic field and produces the magneto-electric rotational torque
Implementation Method 3
ensure accurate alignment of magnetic poles
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present application relates to electric motors, and discloses an electric motor and an electric toy including a stator assembly, a rotor assembly sleeved on the stator assembly, a front end cover assembly, a rear end cover assembly, a three-phase power line, and a data transmission line. The rotor assembly includes a magnetic ring, a magnetic knitting frame, an iron core, several tile-shaped magnets, a rotating shaft, and a rotor end plate. A positioning slot is arranged between adjacent tile-shaped magnets. The magnetic knitting frame is provided with a positioning boss that is inserted into the structure of the positioning slot, so that the magnetic poles of the magnetic ring correspond to the tile-shaped magnet. This improves the positioning accuracy of the rotor assembly of the electric motor, enhances the accuracy of the induction components used for sensing the tile-shaped magnet, and improves the performance of the electric motor.