Halbach Rotor Assembly With Filler-Based Magnet Oxidation Protection
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Solution Overview
Problem
Existing rotary electric machine rotors for automotive applications face challenges in simplifying the assembly of permanent magnets while ensuring their protection from atmospheric agents.
Innovation Solution
A rotor design featuring axially oriented permanent magnets arranged in a Halbach array on the outer surface of a support cylinder, with end discs providing balancing and axial containment, allowing for easy assembly and protection through a filler-filled space between the magnets and the discs, which prevents oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If permanent magnets are arranged on the outer surface of the support cylinder with end discs at axial distance, then assembly is simplified, but protection from atmospheric agents is compromised
Solution Approach 1:
A filler material is introduced as an intermediary substance between the permanent magnets and the atmospheric environment. The filler occupies the space between the radially outer portion of the end discs and the permanent magnets, creating a protective barrier that prevents direct contact with atmospheric agents while maintaining the axial distance configuration for simplified assembly.
Solution Approach 2:
The filler material serves as a sacrificial protective layer that can be easily applied and provides sufficient protection against oxidation. This disposable-like protective measure simplifies the overall structure by eliminating the need for complex sealing mechanisms while adequately protecting the permanent magnets.
2Ease of operation
If end discs are positioned at non-zero axial distance from permanent magnets, then assembly is easier, but protection capability is reduced
Solution Approach 1:
The filler material acts as a mediator that bridges the gap created by the axial distance between the end discs and permanent magnets. This intermediary substance maintains the operational advantage of easy assembly while compensating for the reduced protection capability by providing a dedicated protective layer in the intervening space.
Data Source
AI summary
A rotor for a rotary electric machine and having: a support cylinder, which has an outer surface and a central cavity; a plurality of permanent magnets, which are axially oriented, rest on the outer surface of the support cylinder and are arranged beside one another around a rotation axis to form a closed ring; and two end discs, which are arranged at the axially opposite ends of the support cylinder and define lateral edges of an annular seat containing the main permanent magnets. A radially outer portion of each end disc extending beyond the outer surface of the support cylinder is arranged at a non-zero axial distance from the corresponding permanent magnets.