Integrated Rotor Material Layer for High-Speed Reluctance Machines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional production methods for dynamoelectric rotary machines, particularly reluctance machines, generate waste and result in delicate, vibration-prone rotors that are prone to noise and limit high-speed operation due to the use of flux barriers cut from large sheets and unstable connections between magnetic and non-magnetic areas.
Innovation Solution
A method for producing a material layer for dynamoelectric rotary machines using an additive process, integrating magnetic flux-conducting and flux-blocking regions with different permeabilities, bonded through heating and compaction, to create a robust, one-piece component that reduces magnetic leakage and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flux barriers are cut or punched from large sheet metal using conventional production methods, then the rotor can be manufactured with magnetic and non-magnetic areas, but waste is generated and the structure becomes delicate and vibration-prone
Solution Approach 1:
The patent combines magnetic flux-conducting regions and flux-blocking regions into a single integrally connected material layer. This eliminates the need for separate cutting and assembly operations, thereby eliminating waste generation while maintaining the required magnetic circuit structure.
Solution Approach 2:
The patent uses a composite material structure where different regions of the material layer have different magnetic permeabilities. This allows the creation of both magnetic flux-conducting regions (μr > 50) and flux-blocking regions (μr < 50) within a single continuous material, eliminating waste from conventional cutting methods.
2Shape
If flux barriers are cut or punched from large sheets, then the rotor structure can be formed, but the rotor becomes delicate and prone to vibrations and noise
Solution Approach 1:
The patent merges the flux-blocking regions into the integral structure of the material layer, eliminating separate components that could vibrate. The continuous material structure provides inherent structural stability while maintaining the flux-blocking function through material composition rather than geometric separation.
3Ease of manufacture
If separate connections are used to join magnetic and non-magnetic areas, then the rotor can be assembled, but the connections are unstable and cumbersome
Solution Approach 1:
The patent eliminates the need for separate connections by integrating both magnetic flux-conducting regions and flux-blocking regions into a single continuous material layer. The integral structure provides inherent stability without requiring additional fastening elements or assembly steps.
4Ease of manufacture
If conventional laminated cores are used, then the rotor can be manufactured, but high speeds cannot be achieved due to delicate structure
Solution Approach 1:
The patent employs a composite material layer with spatially varying magnetic permeability that provides both the structural integrity needed for high-speed rotation and the magnetic circuit functionality. The integral structure eliminates the delicate lamination joints that limit speed in conventional rotors.
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 solution results in a stable, robust rotor structure that supports higher speeds with reduced noise and vibration, eliminating the need for separate connections and minimizing waste generation.
Implementation Method 1
magnetic flux-conducting regions, comprising a first material with a first magnetic permeability μr > 50
Implementation Method 2
at least one flux-blocking region, comprising a second material with a second magnetic permeability μr
Implementation Method 3
bonded through heating and compaction
Implementation Method 4
bonded through heating and compaction
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a material layer (1) for a dynamoelectric rotary machine (6), said material layer (1) comprising magnetic-flux conductive regions (9) having a first material with a first magnetic permeability µr > 50, and at least one flux non-conductive region (11) having a second material with a lower magnetic permeability µr < 5 than the first magnetic permeability, wherein the first material and the second material are integrally joined. The invention further relates to a method for producing a material layer (1) of this type.