DLC-Coated Rotary Machine for Minimal Stator-Rotor Air Gap
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Solution Overview
Problem
The air gap between the stator and rotor in rotary machines, such as superconducting motors, limits the magnetic force and power generation, as increasing the air gap reduces the magnetic force and torque, thereby reducing the overall performance and efficiency of the machine.
Innovation Solution
A rotary machine design featuring a coating layer made of diamond-like carbon (DLC) on the surfaces of the stator and rotor, with a thickness ranging from 1 μm to 100 μm, and a lubricant in the air gap to minimize friction and reduce the air gap distance to between 0.01 mm and 1 mm, enhancing the magnetic flux linkage and mechanical torque power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air gap between stator and rotor is increased to ensure smooth rotation and prevent friction, then the reliability of rotation is improved, but the magnetic force and power decrease
Solution Approach 1:
A coating layer is applied to the surfaces of the stator and rotor that face each other across the air gap. This coating layer acts as an intermediary that reduces friction and prevents direct contact between the stator and rotor, allowing the air gap to be minimized while still ensuring smooth rotation. The coating layer enables the system to achieve both reliable rotation and strong magnetic force by mediating the interaction between the two components.
2Power
If the air gap is reduced to increase magnetic force and power, then the power and efficiency are improved, but the risk of friction and contact between stator and rotor increases
Solution Approach 1:
The coating layer serves as a protective intermediary between the stator and rotor surfaces. It allows the air gap to be reduced to 0.01mm or less for maximum magnetic force while preventing direct metal-to-metal contact. The coating layer absorbs any minor variations and prevents friction, ensuring reliable operation even at minimal air gap distances.
Solution Approach 2:
The invention changes the surface properties of the stator and rotor by applying a coating layer with specific friction-reducing characteristics. This parameter change in surface properties allows the system to operate with a reduced air gap without suffering from friction issues, thereby achieving both high power and reliable rotation.
3Power
If a coating layer is applied to reduce friction and minimize air gap, then the power increases by up to 80%, but the manufacturing complexity increases
Solution Approach 1:
The invention applies a coating layer to change the surface parameters of the stator and rotor. This relatively simple parameter change (adding a coating) produces a dramatic increase in power (up to 80% increase in mechanical torque power) by enabling minimal air gap while reducing friction. The manufacturing complexity increase is offset by the substantial performance gain.
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 implementation of the DLC coating layer significantly increases the mechanical torque power by up to 80% compared to machines without the coating, improving the efficiency and reducing wear and damage by minimizing the air gap and friction between the stator and rotor surfaces.
Implementation Method 1
A rotary machine design featuring a coating layer made of diamond-like carbon (DLC) on the surfaces of the stator and rotor
Implementation Method 2
a lubricant in the air gap to minimize friction and reduce the air gap distance
Implementation Method 3
enhancing the magnetic flux linkage and mechanical torque power
Data Source
AI summary
The present disclosure relates to a rotary machine configured to maximize a power by reducing an air gap between a stator and a rotor, for example, in a rotary machine such as a superconducting motor, and a method for manufacturing the same. The rotary machine may include: a stator; a rotor disposed to be separated from the stator by an air gap and configured to be rotatable; and a coating layer formed on at least one of a first opposite surface of the stator and a second opposite surface of the rotor, the first opposite surface and the second opposite surface facing each other.