Composite Rotor Structure With Curved Webs for Low Mass and Stiffness
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Solution Overview
Problem
Traditional electric motor designs face challenges with high mass, insufficient stiffness, and inability to meet structural requirements for temperature and vibration, leading to inefficiencies and increased complexity and cost.
Innovation Solution
A lightweight rotor design with a composite structure featuring a central hub, outer ring assembly, and back-to-back curved webs made of carbon fiber and epoxy, which provides improved stiffness and torque carrying capacity, and is fabricated using topology optimization and composite manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional electric motor rotor designs are used, then structural strength and stiffness can be maintained, but the mass is high and efficiency is reduced
Solution Approach 1:
The patent applies composite materials by replacing traditional metallic rotor components with carbon fiber reinforced polymer (CFRP) composite structures. The rotor includes a composite hub, composite outer ring, and composite webs made from carbon fiber layers impregnated with epoxy resin, achieving significant mass reduction while maintaining or improving structural strength and stiffness through the high strength-to-weight ratio of carbon composites.
Solution Approach 2:
The patent employs curved web structures connecting the hub to the outer ring, replacing traditional straight or radial support structures. The curved geometry optimizes stress distribution and enhances the torsional stiffness of the rotor, allowing for thinner, lighter web sections that maintain structural integrity while reducing mass.
2Strength
If traditional metallic rotor structures are used, then structural integrity is maintained, but the stiffness to weight ratio is insufficient
Solution Approach 1:
The patent utilizes carbon fiber reinforced polymer composites throughout the rotor structure, including the hub, outer ring, and webs. These composite materials provide superior strength-to-weight and stiffness-to-weight ratios compared to traditional metals, maintaining structural integrity while achieving significant weight reduction for high-performance applications.
Solution Approach 2:
The patent employs multi-layered composite construction with fibers oriented in different directions to achieve three-dimensional structural integrity. The carbon fiber layers are stacked with varying orientations (0°, 90°, ±45°) to withstand multidirectional stresses, creating a structurally optimal design that maximizes strength while minimizing mass.
3Reliability
If conventional rotor designs are used, then manufacturing simplicity is maintained, but the ability to meet temperature and vibration structural requirements is insufficient
Solution Approach 1:
The patent divides the rotor into separable composite components including the hub, outer ring, and webs, which can be manufactured independently using automated composite layup and curing processes. These segments are then assembled using bonded joints or mechanical fasteners, allowing for simplified manufacturing and assembly while maintaining structural integrity under temperature and vibration conditions.
Solution Approach 2:
The patent utilizes the anisotropic properties of composite materials by adjusting fiber orientation, layer thickness, and material composition to optimize performance for specific loading conditions. The composite structure can be tailored to withstand thermal expansion differences and vibration loads by controlling the directional properties of each composite layer.
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 design achieves weight reduction, enhanced mechanical stiffness, and improved efficiency by reducing mass while maintaining structural integrity at high temperatures and rotational speeds, with carbon composites offering dimensional stability and various options for temperature and cost requirements.
Implementation Method 1
back-to-back curved webs made of carbon fiber and epoxy
Implementation Method 2
an interior surface to which the hub flange is adhered and an exterior surface adhered to an inner edge of each of the back-to-back curved webs
Implementation Method 3
each of the back-to-back curved webs exerts a radial spring force on at least one of the central hub and the outer ring assembly
Implementation Method 4
The magnetic elements are configured to interact with the magnetic flux to drive unitary rotation of the rotor-shaft assembly
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A rotor (130) is provided and includes a central hub (140), an outer ring assembly (150) comprising magnetic elements and back-to-back curved webs (161, 162) radially interposed between the central hub (140) and the outer ring assembly (150).