Interlocking Rotor Core Sheets for Higher Flux Density
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Solution Overview
Problem
Conventional permanent magnet motors face issues with low magnetic flux density due to soldering of silicon steel sheets and insufficient combining strength when using adhesive bonding in rotor assemblies, leading to energy loss and structural rigidity problems.
Innovation Solution
A rotor assembly design featuring a shaft with stacked core sheets and permanent magnets, where each core sheet has tooth portions and slots forming magnet channels, allowing for angular arrangement of permanent magnets and enhanced mechanical interlocking through projections and joining holes for increased rigidity and magnetic flux density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple silicon steel sheets are combined via soldering, then the rotor assembly structure is rigid, but the magnetic flux density becomes low
Solution Approach 1:
The rotor assembly is segmented into multiple silicon steel sheets stacked together, with each sheet containing tooth portions and slots. This segmentation allows for optimized magnetic flux paths while maintaining structural integrity through the stacked configuration.
Solution Approach 2:
The invention uses composite construction by stacking multiple silicon steel sheets with embedded permanent magnets, creating a composite structure that combines the mechanical strength of metal sheets with the magnetic properties of permanent magnets to achieve both rigidity and high magnetic flux density.
2Ease of manufacture
If multiple silicon steel sheets are combined via adhesive bonding, then manufacturing is simplified, but the combining strength is insufficient during rapid spinning
Solution Approach 1:
The tooth portions of adjacent silicon steel sheets are nested together, with teeth from one sheet fitting into the spaces between teeth of adjacent sheets. This nesting creates mechanical interlocking that provides sufficient combining strength during rapid spinning while maintaining manufacturing simplicity.
Solution Approach 2:
The invention transitions from planar sheet arrangement to three-dimensional interlocking by adding the vertical stacking dimension with nested tooth portions, creating mechanical engagement in multiple directions that significantly enhances combining strength.
3Quantity of substance
If permanent magnets are arranged with small angular intervals, then magnetic flux density increases, but the angle between adjacent magnets becomes too small
Solution Approach 1:
The invention optimizes the local angular arrangement of permanent magnets within each magnet channel, positioning them at specific angular intervals that maximize magnetic flux density while maintaining practical manufacturing constraints. The angular spacing is optimized locally in each slot rather than uniformly distributed.
Data Source
AI summary
A rotor assembly has a shaft, a core having multiple core sheets, and multiple permanent magnets arranged around the shaft. An angle formed between each adjacent two of the multiple permanent magnets is larger than 0 degree and smaller than or equal to 90 degrees. The multiple core sheets includes multiple stacked major core sheets. Each major core sheet has multiple tooth portions having a projection and a joining cavity. The projections of the tooth portions of one of adjacent two of the major core sheets are inserted into the joining cavities and stacked with the projections of the other one of the two adjacent two major core sheets. The rotor assembly has stable structure and high magnetic flux density.