Individual-Segment Rotor Production Using Curable Non-Magnetic Material
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Solution Overview
Problem
The production of individual-segment rotors for electric machines with flux concentration is hindered by high production costs and complex assembly due to the need for multiple non-magnetic segments and complicated flux guidance, which increases the number of components and assembly complexity.
Innovation Solution
A method involving a shaft with distributed laminated core segments and permanent magnets, where a curable non-magnetic material is used to create a positive radial connection between the segments and the shaft, allowing all segments to be fixed in one production step, reducing the number of components and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual laminated core segments are used to prevent flux short-circuiting, then magnetic flux guidance is improved, but the number of components and assembly complexity increases
Solution Approach 1:
The patent merges multiple individual laminated core segments into a single integrated rotor lamination structure. The rotor lamination includes multiple sectors with magnet-receiving recesses formed directly in the laminated core, eliminating the need for separate individual segments. This integration maintains flux guidance functionality while significantly reducing assembly complexity and component count.
2Reliability
If separate non-magnetic material segments are used for flux guidance between poles, then magnetic flux control is improved, but production cost and manufacturing complexity increase
Solution Approach 1:
The patent combines the flux-guiding function into the rotor lamination structure itself through the formation of magnet-receiving recesses. The rotor lamination is designed with alternating magnetic and non-magnetic material regions that provide flux guidance without requiring separate non-magnetic segments. This integration simplifies manufacturing and reduces production costs while maintaining flux control.
Solution Approach 2:
The rotor lamination serves multiple functions simultaneously: it provides structural support, guides magnetic flux, and contains magnet-receiving recesses. By making the rotor lamination multi-functional, the patent eliminates the need for separate components for each function, thereby reducing production cost and manufacturing complexity.
3Reliability
If multiple individual segments are joined together to form the rotor, then flux guidance is achieved, but the number of joining operations and production time increase
Solution Approach 1:
The patent merges multiple segments into a single integrated rotor lamination that can be produced as one piece or pre-assembled unit. The magnet-receiving recesses are formed directly in the laminated core structure, eliminating the need for multiple joining operations between separate segments. This significantly reduces production time while maintaining flux guidance functionality.
4Reliability
If individual laminated segments are used instead of connected rotor laminations, then flux short-circuiting is prevented, but mechanical stability and simplicity of production decrease
Solution Approach 1:
The patent merges individual laminated segments into a single integrated rotor lamination structure. The laminated core is formed as one piece with magnet-receiving recesses, providing both mechanical stability and flux isolation. The integrated structure eliminates the need for joining operations while maintaining the flux-guiding properties of individual laminations.
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 method enables the production of individual-segment rotors at lower costs while maintaining stability and flux guidance, reducing the complexity of assembly and production costs by using a curable non-magnetic material to fix the segments radially on the shaft.
Implementation Method 1
filling an intermediate space between the shaft and each fixing contour of the laminated core segments with a curable non-magnetic material, so that the cured non-magnetic material forms a positive connection relative to the radial direction with each fixing contour and each laminated core segment is retained on the shaft thereby
Data Source
AI summary
In a method for producing an individual-segment rotor for an electric machine, a shaft is arranged in a mold and a plurality of laminated core segments, which are at a distance from one another, are arranged on the circumference of the shaft in a distributed manner in the mold. The laminated core segments each have a fixing contour for a form closure for radially fixing the laminated core segment on the shaft. In addition, a permanent magnet is arranged between each pair of laminated core segments. An intermediate space between the shaft and each fixing contour of the laminated core segments is filled with a curable nonmagnetic material. The curable nonmagnetic material forms a form closure with respect to the radial direction with each fixing contour, and therefore each laminated core segment is retained on the shaft by the form closure.