Halbach Rotor Assembly with Yoke Magnetization for Easier Build
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Solution Overview
Problem
The existing methods for assembling a Halbach array in a motor rotor face challenges such as difficulty in assembling magnetized magnets due to drag forces, requiring extensive manual processes, and resulting in low productivity and decreased magnetization rates.
Innovation Solution
A method where pre-magnetized magnets are assembled in a tangential direction on a rotary body, with non-magnetized magnets inserted between them, and then magnetized using a magnetization yoke, allowing for automation of the assembly process and reducing interference from magnetic forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetized magnets are assembled to form a Halbach array, then the magnetic field is amplified in the direction toward the stator, but the magnets experience drag force that pushes them in opposite directions making assembly difficult
Solution Approach 1:
The patent applies preliminary action by pre-magnetizing the magnets before assembly. The magnets are magnetized in a tangential direction prior to being assembled on the rotor, which allows them to be positioned without experiencing strong radial drag forces during assembly. This preliminary magnetization step enables easier assembly while maintaining the desired magnetic field amplification effect.
2Manufacturing precision
If magnets are manually assembled one by one by bonding, then the magnets can be positioned correctly, but a large amount of time is required to cure the bonding agent and the process cannot be automated
Solution Approach 1:
The patent applies preliminary action by pre-assembling magnets in groups or patterns before final installation on the rotor. This allows for partial automation of the assembly process while maintaining positioning accuracy, significantly reducing the time required compared to manual one-by-one assembly.
3Ease of manufacture
If non-magnetized magnets are assembled and then magnetized by applying an external magnetic field, then the assembly process is simplified, but the magnetization rate decreases in portions where the magnetic field and magnet positions do not coincide
Solution Approach 1:
The patent applies preliminary action by pre-magnetizing the magnets in a tangential direction before assembly. This ensures that when the magnets are installed on the rotor, they already have the correct magnetization orientation, achieving high magnetization rates without requiring complex external field application processes during assembly.
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
This approach automates the assembly of the Halbach array, significantly reducing process time and costs, while ensuring high magnetization rates and improving the overall efficiency of the magnetic circuit.
Implementation Method 1
magnetizing the non-magnetized magnets by generating a magnetic field after fixing a magnetization yoke to the non-magnetized magnets and the pre-magnetized magnets assembled to the rotor
Data Source
AI summary
A Halbach array assembling method for a motor rotor, and the motor rotor made using that method, can include assembling pre-magnetized magnets, which have magnetization directions, at selected intervals along a tangential direction of a cylindrical rotary body, assembling non-magnetized magnets, which are not magnetized, between the pre-magnetized magnets, placing a magnetization yoke concentric with the non-magnetized magnets and the pre-magnetized magnets, and generating a magnetic field through the non-magnetized magnets and the pre-magnetized magnets using the magnetization yoke to implement a circular Halbach array by magnetizing the non-magnetized magnets.