Composite Permanent Magnet Rotor Without Lamination Bridges
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Solution Overview
Problem
Existing rotor designs face challenges in maintaining structural integrity under high centrifugal forces while minimizing the impact on motor performance, particularly due to the use of additional materials like lamination bridges that affect magnet flux and efficiency.
Innovation Solution
The use of carbon rings and tubes as localized reinforcement, eliminating lamination bridges and minimizing air gaps, allows for improved magnet utilization and structural stability by strategically positioning carbon rings and tubes to balance centrifugal forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional material such as a larger lamination bridge is included at an exterior of the rotor to maintain structural integrity under high centrifugal forces, then structural integrity is improved, but motor performance deteriorates due to the additional material affecting magnet flux
Solution Approach 1:
The patent removes the traditional lamination bridge structure from the rotor design and replaces it with carbon fiber reinforcement integrated into the magnet assembly. This extraction of the separate bridge component eliminates the harmful material that was interfering with magnet flux while maintaining structural integrity through the carbon fiber reinforcement system.
Solution Approach 2:
The patent employs carbon fiber composite materials to reinforce the rotor structure instead of using traditional metal lamination bridges. The carbon fiber provides high strength-to-weight ratio and does not interfere with magnetic flux, thus maintaining both structural integrity under centrifugal forces and optimal motor performance.
2Stability of the object's composition
If traditional rotor designs use additional material to stabilize magnets under centrifugal force, then structural stability is improved, but device complexity increases due to additional components
Solution Approach 1:
The patent merges the structural reinforcement function and magnet stabilization function into a single integrated carbon fiber reinforcement system. Instead of having separate lamination bridges and magnet retaining structures, the carbon fiber reinforcement performs both functions simultaneously, reducing component count and simplifying the overall rotor design.
Solution Approach 2:
The carbon fiber reinforcement structure serves multiple functions: it provides structural stability under centrifugal forces, stabilizes the magnets in place, and maintains rotor integrity. This multi-functional design eliminates the need for dedicated single-function components like traditional lamination bridges.
3Strength
If lamination bridges are used to maintain rotor structure, then structural integrity is improved, but manufacturing time and cost increase
Solution Approach 1:
The carbon fiber reinforcement is pre-formed and integrated into the magnet assembly during the manufacturing process, rather than requiring separate assembly steps for lamination bridges. This preliminary integration of the reinforcement structure into the magnet fabrication process reduces overall manufacturing time and simplifies production.
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 enhances rotor efficiency by maintaining structural integrity and maximizing magnet utilization, reducing fabrication time and cost, and improving speed limits.
Implementation Method 1
A rotor, such as used in an electric motor, for example, is subjected to high centrifugal forces during operation
Data Source
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Figure 3A~3D
AI summary
A system includes a motor including: a stator; and a rotor including: a rotor shaft; a lamination stack including: a lamination yoke including a recess in an outermost surface of the lamination yoke and a first groove in the outermost surface of the lamination yoke; a lamination shoe in the recess of the lamination yoke, the lamination shoe including a second groove in an outermost surface of the lamination shoe; and one or more first magnets in the recess of the lamination yoke, each first magnet of the one or more first magnets including a first magnet groove, wherein the first groove of the lamination yoke, the second groove of the lamination shoe, and the first magnet groove are aligned along a first circumference of the lamination stack as a first lamination stack groove; and one or more carbon rings in the first lamination stack groove.