Drawer Substrate for Permanent Magnet Rotor Positioning
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Solution Overview
Problem
Current methods for assembling a rotor body of a permanent magnet motor require complex and costly steps to precisely position permanent magnets, as the materials are fragile and prone to mechanical damage, leading to inefficiencies and torque ripple effects.
Innovation Solution
A positioning substrate in the form of a drawer with elastic profiles and snap protrusions that allows for easy insertion and precise positioning of permanent magnets into slots without mechanical stress, requiring only two assembly steps and ensuring accurate alignment and fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex positioning substrates with multiple fixation means are used, then positioning precision is improved, but assembly complexity and cost increase
Solution Approach 1:
The positioning substrate utilizes the insertion force itself to activate the elastic profiles, which then automatically provide lateral positioning and axial fixation without requiring separate fixation operations. The system serves itself by converting the assembly force into positioning and securing functions.
Solution Approach 2:
Multiple functions (positioning, lateral centering, axial fixation) are merged into a single positioning substrate component that is inserted in one operation. The elastic profiles and snap protrusions integrate multiple securing mechanisms into one unified structure.
2Reliability
If traditional fixation methods are used, then permanent magnets are securely fixed, but mechanical loads and risk of damage increase
Solution Approach 1:
The elastic profiles are pre-configured to deform elastically during insertion, absorbing mechanical shocks and distributing forces gently on the permanent magnets. This beforehand cushioning prevents sudden impacts that could damage the fragile magnet materials.
Solution Approach 2:
The elastic profiles change their physical state from undeformed to deformed during insertion, allowing them to adapt to the slot dimensions and provide secure fixation without excessive mechanical stress. The material parameters (elasticity) enable force distribution that protects the magnets.
3Manufacturing precision
If multiple assembly steps and tools are used, then positioning accuracy is improved, but productivity decreases
Solution Approach 1:
The positioning substrate is pre-configured with elastic profiles and snap protrusions that automatically activate during a single insertion operation. The preliminary design of the substrate structure enables it to perform multiple positioning and securing functions without requiring intermediate adjustment or fixation steps.
4Ease of operation
If simple positioning structures are used, then assembly ease is improved, but positioning precision deteriorates
Solution Approach 1:
The elastic profiles act as intermediaries between the positioning substrate and the permanent magnets, providing lateral centering and force distribution. The snap protrusions serve as intermediaries for axial fixation, enabling precise positioning through a simple single-step insertion operation.
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 enables a simple, tool-free assembly process with high precision, minimizing mechanical loads and torque ripple effects, resulting in improved motor efficiency and reduced assembly complexity.
Implementation Method 1
the first and second side walls (10, 11) have at their outer sides longitudinally extending profiles (19) which are elastic at least in a direction perpendicular to the outer side
Implementation Method 2
the fourth side wall (13) has a snap protrusion (18) which protrudes beyond an upper side wall edge
Data Source
Figure 1~5
AI summary
A positioning substrate P for at lest one permanent magnet M of a slotted rotor R of a permanent magnet motor has the shape of a rectangular drawer 9 consisting of four narrow vertical side walls 10-13 and a bottom wall, the side walls bounding an open permanent magnet insertion side and a receiving space, the four side walls having integrated laterally and longitudinally acting drawer fixation structures. In a rotor R of a permanent magnet motor the positioning substrate P containing at least one permanent magnet M is inserted into a slot S and is fixed in lateral and longitudinal directions in the slot by form-fit and/or force-fit co-action between drawer fixation structures and the rotor body 1 in order to precisely position at least one permanent magnet M in the slot S of the rotor body 1.