Convex-Concave Stator Rotor Assembly Magnetic Loss Reduction
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Solution Overview
Problem
Current electric machine designs, such as induction and permanent-magnet motors, face challenges in reducing energy loss and manufacturing costs due to high surface magnetic fields at the edges of magnets and the use of expensive rare earth materials, which affects efficiency and torque density.
Innovation Solution
The design incorporates a mover and stator assembly with convex and concave magnetic parts, where the width of the convex parts is smaller than the concave parts, optimizing the magnetic circuit to reduce side magnetic loss and enhance flux density, thereby increasing efficiency and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional flat magnetic parts are used in stator and rotor, then the manufacturing process is simple, but the surface magnetic field is higher at the edges causing increased magnetic loss and reduced efficiency
Solution Approach 1:
The patent applies asymmetry by designing convex parts on one magnetic component and corresponding concave parts on the other, replacing the traditional symmetric flat configuration. This asymmetric design concentrates the magnetic field in the center region, reducing the harmful edge effects and minimizing magnetic loss while maintaining manufacturing feasibility through standard stamping processes.
2Power
If rare earth magnets are used to increase magnetic energy product, then the motor performance and torque density improve, but the manufacturing cost increases significantly
Solution Approach 1:
The patent applies local quality by concentrating the magnetic field strength where it is most needed - in the center region between the convex and concave parts. This localized field concentration allows for reduced overall magnet material usage while maintaining high torque density in the critical operational zone, thereby lowering the cost of rare earth materials without sacrificing motor performance.
3Loss of energy
If the width of convex parts is made smaller than concave parts, then the magnetic circuit is optimized and side magnetic loss is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies segmentation by dividing the magnetic interaction area into distinct convex and concave regions with clearly defined boundaries. The convex parts protrude from one surface while concave parts are recessed in the opposing surface, creating discrete zones that guide magnetic flux. This segmented structure naturally contains the magnetic field and reduces side losses, while the clear geometric definitions facilitate consistent manufacturing.
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 configuration enhances the magnetic flux density and torque output, leading to improved energy efficiency and lower manufacturing costs by directing and gathering the magnetic circuit, while also reducing side magnetic losses.
Implementation Method 1
The width of each of the convex parts is smaller than the width of each of the concave parts... enhancing the magnetic flux density and torque output, leading to improved energy efficiency
Data Source
AI summary
A mover and stator assembly of an electric machine includes at least one stator and at least one rotor. Each stator includes multiple magnetic components each including a first surface and a salient portion protruding from the first surface. The rotor includes multiple second magnetic components each including a second surface and a groove located on the second surface. The first surfaces face the second surfaces, and the width of each salient portion is less than that of each groove.