Exchangeable Stator and Rotor Rings for Multi-Class Motor Production
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Solution Overview
Problem
Manufacturing different motor classes proves costly and inefficient due to the need for distinct stator and rotor assemblies, which require separate manufacturing processes and equipment.
Innovation Solution
A manufacturing process that selects exchangeable stator and rotor components from groups consisting of spacer rings and axially magnetized magnet rings, allowing the same equipment to produce various motor classes by swapping components, such as stator spacer rings, axially magnetized stator magnet rings, rotor spacer rings, and rotor magnet rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If distinct stator and rotor assemblies are manufactured for different motor classes, then each motor class achieves its specific performance requirements, but manufacturing costs increase and production efficiency decreases
Solution Approach 1:
The patent implements universality by designing stator and rotor assemblies with interchangeable components that can be configured to produce different motor classes (SR, PPMT, IPM) using the same manufacturing equipment. The modular architecture allows a single production line to manufacture multiple motor types by swapping components such as stator magnet rings, rotor magnet rings, and spacer rings, thereby improving productivity while maintaining the specific performance requirements of each motor class through appropriate component selection
2Reliability
If separate manufacturing processes are used for different motor classes, then each motor class can be optimized independently, but manufacturing complexity and costs increase
Solution Approach 1:
The patent applies segmentation by dividing the stator and rotor assemblies into modular, interchangeable components (stator magnet rings, rotor magnet rings, spacer rings) that can be independently selected and assembled. This segmentation allows each component to be optimized for specific motor classes while using the same base manufacturing process, reducing overall manufacturing complexity while maintaining the ability to independently optimize each motor class through component selection
3Reliability
If multiple specialized manufacturing equipment are acquired for different motor classes, then production quality for each class is maintained, but capital investment and operational costs increase
Solution Approach 1:
The patent implements universality in manufacturing by designing the stator and rotor assemblies with standardized, interchangeable components that can be produced on the same manufacturing equipment regardless of the target motor class. This approach allows a single production line to manufacture SR, PPMT, and IPM motors with consistent quality standards while avoiding the need for multiple specialized equipment investments, thereby reducing capital and operational costs while maintaining production quality
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
Enables cost savings by using the same manufacturing equipment to produce multiple motor classes, including SR, PPMT, and IPM motors, with the ability to transform motor classes by exchanging stator and rotor components, thereby reducing production costs and increasing efficiency.
Implementation Method 1
A rotating machine, such as a motor, includes a stator assembly, a rotor assembly, and an air gap between the stator assembly and the rotor assembly defining a rotor-stator interface
Implementation Method 2
The first input comprises an exchangeable stator component selected from a stator component group consisting of a stator spacer ring and an axially magnetized stator magnet ring
Implementation Method 3
the axially magnetized stator magnet ring selected as a solid axially magnetized ring magnet
Data Source
AI summary
Exchangeable stator components are selected and exchangeable rotor components are selected to transform a motor from one motor class to another motor class. A motor comprises at least two stator rings, at least two outer rotor rings, a first input, and a second input. The first input comprises an exchangeable stator component selected from a stator component group consisting of a stator spacer ring and an axially magnetized stator magnet ring, the axially magnetized stator magnet ring comprising a solid axially magnetized ring magnet. The second input comprises an exchangeable rotor component selected from a rotor component group consisting of a rotor spacer ring and an axially magnetized rotor magnet ring. The first input and the second input determine a motor class for the motor, the exchangeable stator component being exchangeable for a different exchangeable stator component from the stator component group to manufacture another motor having a different motor class, the exchangeable rotor component being exchangeable for a different exchangeable rotor component from the rotor component group to manufacture another motor having another different motor class.