Compressor Motor Rotor Magnetization with Injection-Molded Cover
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Solution Overview
Problem
Compressor motors with inserted magnets face issues such as magnet movement and deformation during low-speed rotation, magnet powder contamination in the refrigeration cycle, and complexities in the rotor manufacturing process due to polarity matching requirements, leading to inefficiencies and potential damage.
Innovation Solution
A compressor motor design featuring a rotor with a core, injection-molded covers that fill spaces between magnets and the core, and rotation prevention guides to stabilize the magnets and prevent rotor rotation during magnetization, allowing for accurate magnetization and improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If magnets are inserted into the rotor for IPM type configuration, then motor efficiency is improved, but magnets may move and deform during low-speed rotation
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the rotor core before magnet insertion. These recesses are specifically designed to accommodate the magnets and prevent their movement during operation. The recesses are created in advance through machining or molding processes, establishing the constraint structure before the magnets are placed, thereby preventing magnet displacement and deformation during low-speed rotation while maintaining the efficiency benefits of IPM configuration.
Solution Approach 2:
The patent introduces an intermediary element - the recess structure - that mediates between the magnet and the rotor core. This recess acts as a intermediary space that holds the magnet in place, preventing direct contact and potential deformation between the magnet and the rotating rotor components. The recess serves as a buffer and positioning mechanism, allowing the magnet to maintain its shape and position while still functioning effectively in the IPM configuration.
2Ease of manufacture
If magnets are pre-magnetized before insertion, then polarity arrangement is simplified, but manufacturing process time increases due to polarity verification
Solution Approach 1:
The patent applies preliminary action by pre-magnetizing the magnets before insertion into the rotor, but combines this with a simplified positioning system. The pre-magnetized magnets are inserted into specifically designed recesses that automatically orient them correctly based on their magnetic polarity. This preliminary magnetization, combined with the recess structure, eliminates the need for time-consuming polarity verification during assembly, as the recess geometry guides the magnets into their correct orientation automatically.
3Measurement precision
If guide hole and pin method is used for magnetization positioning, then rotor matching with magnetization device is achieved, but pin damage and cover breakage occur
Solution Approach 1:
The patent applies the taking out principle by removing the vulnerable pin component from the magnetization positioning system. Instead of using a pin that protrudes through the cover and can be damaged, the patent uses recesses formed directly in the rotor core. The magnetization device positions itself relative to these recesses without requiring external pins or protrusions that could break. This extraction of the pin element eliminates the source of damage while maintaining positioning accuracy through the recess geometry.
Solution Approach 2:
The patent applies preliminary action by pre-forming the recesses in the rotor core before the magnetization process. These recesses serve as built-in positioning features that guide the magnetization device into the correct position. By having the positioning structure already in place as part of the rotor itself, there is no need for separate pins or external alignment mechanisms that could fail or cause damage during the magnetization process.
4Productivity
If magnets are inserted without polarity consideration, then manufacturing process is simplified, but accurate magnetization requires additional positioning steps
Solution Approach 1:
The patent introduces the recess structure as an intermediary that facilitates both rapid magnet insertion and accurate positioning for magnetization. The recesses allow magnets to be quickly inserted without polarity consideration, as they can be placed in any orientation initially. The recess geometry then serves as a mediator during the magnetization process, guiding the magnetization device to the correct position and orientation automatically, thereby maintaining high productivity while ensuring accurate magnetization without adding complex positioning mechanisms.
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 solution effectively prevents magnet movement and deformation, enhances rotor stability, simplifies the manufacturing process by ensuring accurate magnetization, and reduces the risk of damage, thereby improving motor efficiency and reliability.
Implementation Method 1
magnetizing the plurality of magnets through application of a magnetization power to the magnetization yoke
Implementation Method 2
the magnets, which initially have no polarity, may have the polarities through a magnetization process in a state where the magnets are inserted into the rotor. Since the magnets have the polarities, the rotor may be rotated through electrical interaction with the stator on the inside of the stator.
Data Source
AI summary
A compressor motor and a method for magnetizing a rotor thereof are provided. The compressor motor includes a stator and a rotor configured to electromagnetically interact with the stator to be rotated, wherein the rotor includes a core, a plurality of magnets inserted into the core, and a cover configured to cover both end portions of the core and to be injection-molded so as to fill accommodation spaces that are formed between the core and the plurality of magnets.