Flat Multi-Pole Magnet Generator with Interlaced Claw-Poles
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Solution Overview
Problem
Conventional hub-type dynamo electric generators are bulky, costly, and have low efficiency due to their tubular magnet design, which causes magnetic flux to drop and interfere with each other, making them unsuitable for miniaturization and high-performance applications.
Innovation Solution
A compact electric generator design featuring a flat multi-pole magnet of disc shape with an integrally formed iron core and claw-pole set, where the inner and outer claw-poles are interlaced to guide magnetic flux effectively, allowing for efficient power generation even at low rotation speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a tubular magnet design is used in conventional hub-type dynamos, then the generator can be compact, but the magnetic flux drops and interferes with each other causing low efficiency
Solution Approach 1:
The tubular magnet is segmented into multiple independent pole pieces arranged radially around the stator pins. Each pole piece is separated by non-magnetic material, preventing magnetic flux interference between adjacent poles while maintaining the compact tubular structure. This segmentation allows magnetic flux to concentrate effectively in each pole region without being deflected by adjacent poles.
Solution Approach 2:
The pole pieces are designed with optimized local magnetic properties, using high-permeability magnetic material concentrated at the pole faces that contact the stator pins. The magnetic flux path is locally enhanced at critical interfaces while non-magnetic materials are strategically placed in regions where flux interference would occur, creating localized magnetic circuits that maximize efficiency.
2Device complexity
If multiple poles are arranged in alternating manner wrapped by tube-like magnet, then the generator structure is compact, but the magnetic lines are deflected more than twice causing reduced magnetic flux through the coil
Solution Approach 1:
The alternating multi-pole structure is segmented into discrete pole pieces rather than a continuous tubular magnet. Each pole piece creates a localized magnetic circuit with the stator pins, reducing the path length and number of deflections for magnetic flux. The segmentation breaks the long flux path into shorter segments, minimizing total deflection angle.
Solution Approach 2:
Non-magnetic intermediary materials are placed between adjacent pole pieces to act as magnetic flux barriers, preventing flux from one pole from deflecting into adjacent poles. This intermediary structure guides flux through the intended path only, reducing unnecessary deflections and maintaining higher flux density through the coil.
3Ease of manufacture
If conventional iron core with stacked silicon steel sheets is used, then the generator can be assembled, but the formation and installation is complicated and time-consuming
Solution Approach 1:
The iron core is merged with the stator pins to form an integrated component. Instead of separately assembling stacked silicon steel sheets onto the stator pins, the magnetic core material is formed as a single piece that incorporates both the core structure and the pin mounting features, dramatically reducing assembly steps and time.
Solution Approach 2:
The integrated iron core design serves multiple functions simultaneously: it provides the magnetic circuit path, acts as the structural support for stator pins, and serves as the mounting interface for the coil assembly. This multi-functional design eliminates the need for separate components and assembly operations.
4Reliability
If the magnet is shaped like a tube wrapping around stator pins, then the generator structure is complete, but the resulting electric generator is bulky and costly
Solution Approach 1:
The tubular magnet is segmented into thin radial pole pieces rather than a solid tube, reducing the overall volume and mass while maintaining the structural framework. The segmented design allows the stator pins to be positioned within the radial gaps, creating a more compact arrangement that reduces generator volume.
Solution Approach 2:
The magnetic circuit is transitioned from a three-dimensional tubular volume to a two-dimensional radial arrangement of thin pole pieces. This dimensional change reduces the volume occupied by the magnet while maintaining the essential magnetic circuit functionality, making the generator more compact.
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 design results in a compact, lightweight, and cost-effective electric generator with improved power density and efficiency, capable of generating satisfactory voltage at low rotation speeds, suitable for portable applications and reducing magnetic resistance.
Implementation Method 1
there is a solenoid coil (60), wound on the outside of the iron core (40)
Implementation Method 2
a flat multi-pole magnet of disc shape or other geometrical shape, being integrally formed with an iron core working cooperatively with a claw-pole set arranged wrapping a solenoid coil, so that its voltage output is satisfactory even when operating at low rotation speed
Data Source
AI summary
An electric generator is disclosed, which comprises: at least a magnet, each having more than two poles; and at least a claw-pole set, each being composed of an inner claw-pole and an outer claw-pole; wherein, the inner claw-pole and the outer claw-pole are interlaced arranged and used for guiding magnetic flux; the inner claw-pole is connected to an iron core whose outer diameter is smaller than the magnet and thus the loop of the inner claw-pole and the outer claw-pole is conducted; the core is winded by a solenoid coil; the number of claws of the inner claw-pole is the half of the pole number of the magnet while the outer claw-pole is the same, so that, as the magnet is move relative to the claw-pole set, the magnetic flux passing through the solenoid coil will change continuously and thus an induction electromotive force is generated.