Integrated Interpolar Magnet for Rotor Flux Leakage Reduction
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Solution Overview
Problem
Existing motor rotors with Randell-type structures using permanent magnet field systems face challenges in increasing output while minimizing the number of components, leading to increased assembly time and costs due to the need for multiple interpolar magnets.
Innovation Solution
A rotor design featuring first and second hook-shaped magnetic poles with integrated auxiliary magnets, where the first and second hook-shaped magnetic poles are alternately arranged, and a field magnet is placed between them, with auxiliary magnets magnetized in the axial direction to reduce magnetic flux leakage, and interpolar magnet portions are integrated to cover the gaps between the poles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple separate interpolar magnets are provided between each pair of hook-shaped poles, then magnetic flux leakage is reduced and motor output is improved, but the number of components increases and assembly time and labor increase
Solution Approach 1:
Multiple separate interpolar magnets are merged into a single integrated interpolar magnet component. The patent describes an interpolar magnet with a continuous body that includes multiple magnet portions arranged between different pairs of hook-shaped poles, eliminating the need for multiple separate magnet components and reducing assembly complexity while maintaining the magnetic flux rectification function.
Solution Approach 2:
The integrated interpolar magnet serves multiple functions simultaneously: it provides magnetic flux rectification between multiple pairs of hook-shaped poles, maintains mechanical spacing between components, and provides structural support. This multi-functional design reduces the overall component count while achieving the same technical effects as multiple separate magnets.
2Power
If multiple separate interpolar magnets are provided between each pair of hook-shaped poles, then magnetic flux leakage is reduced and motor output is improved, but assembly time and labor increase
Solution Approach 1:
Multiple separate interpolar magnets are merged into a single integrated interpolar magnet component. The patent describes an interpolar magnet with a continuous body that includes multiple magnet portions arranged between different pairs of hook-shaped poles, eliminating the need for multiple separate magnet components and reducing assembly complexity while maintaining the magnetic flux rectification function.
Solution Approach 2:
The interpolar magnet is pre-assembled as a single integrated component with all magnet portions positioned correctly during manufacturing. This preliminary integration eliminates the need for time-consuming on-site assembly of multiple separate magnets, reducing assembly time and labor while ensuring proper positioning and alignment.
3Power
If multiple separate interpolar magnets are provided between each pair of hook-shaped poles, then motor output is improved, but production costs increase
Solution Approach 1:
Multiple separate interpolar magnets are merged into a single integrated interpolar magnet component. The patent describes an interpolar magnet with a continuous body that includes multiple magnet portions arranged between different pairs of hook-shaped poles, eliminating the need for multiple separate magnet components and reducing assembly complexity while maintaining the magnetic flux rectification function.
Solution Approach 2:
The integrated interpolar magnet serves multiple functions simultaneously: it provides magnetic flux rectification between multiple pairs of hook-shaped poles, maintains mechanical spacing between components, and provides structural support. This multi-functional design reduces the overall component count while achieving the same technical effects as multiple separate magnets.
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 design enhances motor output efficiency, reduces the number of components, and simplifies assembly by minimizing magnetic flux leakage and integrating multiple magnet functions into fewer components, thereby lowering production costs and assembly complexity.
Implementation Method 1
The field magnet is magnetized along the axial direction so that the first hook-shaped poles function as first poles and the second hook-shaped poles function as second poles
Implementation Method 2
Each of the interpolar magnet portions is arranged in a void between the first hook-shaped poles and the second hook-shaped poles and magnetized in the circumferential direction
Data Source
AI summary
A rotor includes a first rotor core, a second rotor core, a field magnet, and an auxiliary magnet. The first rotor core includes a first core base and a plurality of first hook-shaped poles. The second rotor core includes a second core base and a plurality of second hook-shaped poles. The first and second hook-shaped poles are alternately arranged in a circumferential direction of the rotor. The field magnet is arranged between the first and second core bases in an axial direction. The field magnet cause the first hook-shaped poles to function as first poles and the second hook-shaped poles to function as second poles. The auxiliary magnet includes at least two interpolar magnet portions, which are integrally formed. Each interpolar magnet portion is arranged in a void between the first hook-shaped pole and the second hook-shaped pole and magnetized in the circumferential direction.