Cylindrical Rotor Magnet and Stator Core Design for Torque Ripple Reduction
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Solution Overview
Problem
Permanent magnet synchronous motors face challenges in machining and assembly due to the separated structure of the rotor magnet and tooth sockets in the stator core, leading to fluctuating torque and difficulty in achieving high-precision speed and position control, as well as tedious and non-automated production processes.
Innovation Solution
A cylindrical rotor magnet and stator core design without tooth sockets, allowing for sinusoidal magnetic induction and simplified assembly, with coil windings formed by superposing coils in a sequence and inserted into the core for enhanced magnetic field concentration and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tooth socket structure is used in the stator core for positioning coil windings, then the coil windings can be positioned, but the output torque fluctuates and high-precision speed and position control is difficult to realize
Solution Approach 1:
The invention removes the tooth socket structure from the stator core, extracting the problematic element that caused torque fluctuation. The core is designed as a smooth cylindrical structure without tooth sockets, eliminating the source of torque ripple while maintaining coil positioning through alternative means.
2Ease of manufacture
If a separated structure is used for the rotor magnet distributed in the rotor core, then the magnet can be installed, but the magnet easily drops during working and the machining and assembly process is tedious
Solution Approach 1:
The invention merges the rotor magnet with the rotor core by directly coupling the cylindrical magnet to the rotating shaft, forming an integrated rotor assembly. This eliminates the separated structure that caused magnet dropout, while the cylindrical shape enables automated machining and assembly processes.
Solution Approach 2:
The rotor magnet is designed as a cylindrical shape rather than a separated distributed structure. This curved, continuous form improves structural integrity, prevents magnet dropout during rotation, and allows for efficient automated machining using cylindrical grinding or turning processes.
3Ease of manufacture
If a tooth socket structure is used in the stator core, then coil windings can be positioned, but the machining process becomes complex and automatic production is difficult to realize
Solution Approach 1:
The tooth socket structure is completely removed from the stator core design. The core is manufactured as a smooth cylindrical component that can be produced through automated processes such as precision turning or extrusion, eliminating the complex machining operations required for tooth socket creation while maintaining coil positioning capability.
4Productivity
If a cylindrical magnet structure is used in the rotor, then the magnet is convenient to machine and assemble, but the magnetic field distribution may be affected
Solution Approach 1:
The invention optimizes the cylindrical magnet's parameters including diameter, length, and magnetic material properties to achieve the desired magnetic field distribution. By carefully selecting and adjusting these parameters, the cylindrical shape produces a sinusoidal magnetic induction waveform in the air gap, achieving both manufacturing efficiency and precise magnetic field control.
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 design facilitates efficient machining and assembly of the motor components, enabling high-precision speed and position control with improved assembly efficiency and automation, and a consistent output torque.
Implementation Method 1
The coil windings generate a magnetic field after power-on to drive the rotor to rotate
Implementation Method 2
the magnetic induction intensity of the air gap is completely in sinusoidal distribution
Data Source
AI summary
A permanent magnet synchronous motor is provided in the present disclosure. The permanent magnet synchronous motor includes a rotor and a stator, wherein the rotor comprises a rotating shaft and a cylindrical magnet surrounding the rotating shaft, the stator comprises a base, a cylindrical core received in the base and surrounding the magnet and coil windings assembled with the core, the coil windings are symmetrical about the center axis of the core, the coil winding comprises a plurality of coils inserted into the core, each coil comprises a body part and extended parts respectively extended from two ends of the body part, a plurality of body parts are superposed and disposed in the core, a plurality of extended parts are respectively extended in the radial direction of the core and fixed on two end faces of the core, and the plurality of extended parts are partially superposed and distributed in a step shape.