Magnet Generator Flywheel Vent Holes Cooling
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Solution Overview
Problem
Existing magnet generators face challenges with high fabrication costs and reduced productivity due to complex manufacturing processes for fins and vent holes, which affect cooling efficiency and output current, and require extensive burr treatment after cutting.
Innovation Solution
The magnet generator features a bowl-shaped flywheel with vent holes having droop or curved shaped base parts, formed through forging, enhancing cooling efficiency and eliminating the need for burr treatment, thereby reducing costs and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fins are made integral with the flywheel by insert molding to enhance cooling performance, then cooling efficiency is improved, but fabrication cost increases due to large number of man-hours and dedicated resin forming mold
Solution Approach 1:
The invention merges the cooling function directly into the flywheel structure by forming cooling holes with droop-shaped base portions integrally with the flywheel body through forging. This eliminates the need for separate fins and dedicated molds, reducing fabrication complexity and cost while maintaining effective cooling performance.
Solution Approach 2:
The invention changes the geometric parameter of the cooling holes by forming droop-shaped base portions instead of simple cylindrical holes. This shape modification enhances cooling efficiency by improving airflow patterns while being achievable through standard forging processes, thus not increasing fabrication cost.
2Temperature
If protuberances are formed at peripheral edge parts of vent holes by plastic deformation to generate turbulence, then cooling performance is enhanced, but fabrication process becomes complicated with burring working
Solution Approach 1:
The invention merges the turbulence-generating function into the vent hole structure itself by forming droop-shaped base portions during the forging process. This eliminates the need for separate protuberances and subsequent burring operations, simplifying the fabrication process while maintaining enhanced cooling performance through natural turbulence.
3Strength
If plate thickness of the flywheel is increased to ensure rigidity of the flywheel bottom surface, then structural strength is improved, but working time increases and burr treatment cost increases
Solution Approach 1:
The invention merges the hole formation process into the forging step itself, creating vent holes with droop-shaped base portions simultaneously with the flywheel body formation. This eliminates subsequent cutting operations and burr treatment, reducing working time and improving productivity while maintaining flywheel rigidity through optimized hole geometry.
4Temperature
If vent holes of large area are provided to enhance cooling performance, then power generation efficiency is improved, but rigidity of the flywheel bottom surface is reduced
Solution Approach 1:
The invention applies local quality enhancement by forming droop-shaped base portions at specific locations within the vent holes. This localized geometric modification improves cooling performance through enhanced airflow patterns while minimizing the overall impact on flywheel rigidity, allowing large-area vent holes without compromising structural strength.
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 droop or curved shape of vent hole base parts improves cooling and power generation efficiency, reduces fabrication costs, and simplifies the manufacturing process, leading to enhanced productivity and increased output current.
Implementation Method 1
The power generation coil, disposed in opposition to the magnets within the flywheel, generates power under an electromagnetic induction action with the magnets
Implementation Method 2
The flywheel has a plurality of vent holes in the bottom portion thereof, and a droop or curved shape is formed at, at least, one hole base part of each of the vent holes
Data Source
AI summary
A magnet generator including a bowl-shaped flywheel which is formed of a cylindrical portion and a bottom portion on one end side of the cylindrical portion, a plurality of magnets which are arranged on the inner peripheral surface of the cylindrical portion of the flywheel, and a power generation coil which generates power under an electromagnetic induction action with the magnets and which is disposed in opposition to the magnets within the flywheel, wherein the flywheel has a plurality of vent holes in its bottom portion, and the hole base part of each of the vent holes is formed in a droop or curved shape. Owing to the droop or curved shape, a cooling efficiency is enhanced, and a job for treating burrs and laps after cutting working can be relieved to enhance a productivity.