Composite Rotor Magnet Retention for High-Speed Axial Machines
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Solution Overview
Problem
Existing rotors with composite structures face challenges in maintaining strength and preventing overheating at high rotational speeds, particularly due to centrifugal forces, while also requiring a large number of parts for construction.
Innovation Solution
A rotor with a composite structure featuring a fiber-reinforced matrix that includes peripheral recesses for magnets, secured by unidirectional fiber straps and attachment means, which provide enhanced strength and retention, allowing for reduced mass and hoop size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If composite materials are used to reduce rotor mass and prevent overheating, then thermal performance is improved, but structural strength decreases due to centrifugal forces
Solution Approach 1:
The patent employs a composite structure combining fiber-reinforced polymer material with metallic elements. The composite material support (resin reinforced with fibers) provides thermal management benefits while metallic reinforcement elements restore structural strength to withstand centrifugal forces at high rotational speeds
Solution Approach 2:
The patent applies different material properties to different regions of the rotor. The composite material is used in areas requiring thermal management, while metallic reinforcement is strategically placed in areas requiring high strength to counteract centrifugal forces, creating localized material optimization
2Strength
If a hoop is added to contain magnets under centrifugal force, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The patent merges the function of the containment hoop with the composite material support structure itself. The radial and tangential fibers in the composite support inherently provide the containment function, eliminating the need for a separate hoop structure and reducing overall device complexity
3Strength
If frame elements are used to house magnets, then strength is improved, but the number of parts increases
Solution Approach 1:
The patent combines multiple structural functions into a single integrated composite support structure. The radial fibers, tangential fibers, and metallic reinforcement elements work together as one unified component system, eliminating the need for separate frame elements and reducing the total number of parts
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 rotor achieves high strength and resistance to centrifugal forces at high speeds with minimal overheating, while reducing the number of parts required, thus meeting new market demands for improved performance.
Implementation Method 1
the rotor being characterized in that it includes attachment means distributed peripherally around the passage of said shaft, and in that said radial or substantially radial elements, of several recesses, whether or not neighbors, as well as the segments connecting the said radial or substantially radial elements in pairs, for one or more recesses, whether or not neighbors, consist of at least one strap, resulting from the winding of continuous unidirectional fibers passing between the said magnets
Implementation Method 2
said composite material support including peripheral recesses each able to contain a magnet, each of said recesses being delimited, at least laterally, by two radial or substantially radial elements and on the side of the periphery of the rotor by a segment connecting said two radial or substantially radial elements
Data Source
AI summary
Composite-structure rotor for axial flow electrical machines comprising at least one stator and a rotor rigidly connected to a shaft to be rotated, in the shape of a disc and comprising a plurality of permanent magnets supported by a support made of a composite material rigidly connected to the shaft to be driven and constituted by a reinforced fibre matrix. The rotor comprises distributed attachment means for the radial elements and segments, which connect the elements in pairs, forming recesses, and which comprise at least one strap resulting from the winding of continuous unidirectional fibres passing between the Composite-structure rotor for axial flow electrical machines comprising at least one stator and a rotor rigidly connected to a shaft to be rotated, in the shape of a disc and comprising a plurality of permanent magnets supported by a support made of a composite material rigidly connected to the shaft to be driven and constituted by a reinforced fibre matrix. The rotor comprises distributed attachment means for the radial elements and segments, which connect the elements in pairs, forming recesses, and which comprise at least one strap resulting from the winding of continuous unidirectional fibres passing between the magnets, on the outside edge thereof, as well as on each of the attachment means, in order to form a collective retention of the magnets.