IPM Motor Rotor Sensor Magnet Segmentation for Resin Flow
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Solution Overview
Problem
The flowability of liquid resin is degraded when a sensor magnet is fixed to a rotor core through resin sealing in existing interior permanent magnet motors, leading to insufficient resin sealing and potential assembly errors.
Innovation Solution
A rotor design with a sensor magnet featuring an annular base and projecting portions with tapered inner peripheries, arranged at intervals, improves resin flowability by creating recessed and projecting areas that facilitate resin flow around the sensor magnet during resin sealing, preventing resin sealing failures and ensuring accurate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor magnet is fixed to the rotor core through resin sealing, then the sensor magnet is securely attached to the rotor core, but the flowability of liquid resin in the mold is degraded
Solution Approach 1:
The sensor magnet is divided into multiple segments separated by grooves, transforming it from a single solid structure into segmented components. This segmentation creates flow paths for the liquid resin to pass through, resolving the contradiction by allowing both secure attachment and good resin flowability.
Solution Approach 2:
The sensor magnet incorporates groove structures that function similarly to porous features, creating channels through which liquid resin can flow. These grooves allow the resin to penetrate and seal around the sensor magnet segments, maintaining both attachment reliability and resin flowability.
2Device complexity
If the sensor magnet serves as a wall against liquid resin flowing in the mold, then the sensor magnet structure is simple, but the flowability of liquid resin is degraded
Solution Approach 1:
By segmenting the sensor magnet with grooves, the structure remains relatively simple while fundamentally changing the resin flow behavior. The grooves create natural flow paths without requiring complex mold modifications or additional components.
Solution Approach 2:
Instead of making the sensor magnet a solid wall that blocks resin flow, the invention inverts the approach by creating grooves that actively guide and facilitate resin flow through the magnet structure, transforming from a blocking element to a flow-enabling structure.
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 improved resin flowability ensures effective resin sealing and prevents assembly errors, enhancing the reliability and efficiency of the rotor assembly process in interior permanent magnet motors.
Implementation Method 1
the sensor magnet includes a plurality of projecting portions projecting toward the rotor core from a first surface, which is a surface of the base portion on a side opposed to the rotor core, and the plurality of projecting portions each have a tapered portion on an inner periphery thereof
Implementation Method 2
injecting a resin in a liquid state through the injection port and curing the resin
Data Source
AI summary
Provided is a rotor for an IPM motor, including: a rotor core; permanent magnets embedded in the rotor core; a sensor magnet provided at one end of the rotor core; and a resin configured to fix the sensor magnet to the rotor core by covering the sensor magnet, wherein the sensor magnet includes: a base portion having an annular shape; and a plurality of projecting portions projecting toward the rotor core from a first surface, which is a surface of the base portion on a side opposed to the rotor core, and wherein the plurality of projecting portions each have a tapered portion on an inner periphery thereof, and are arranged at intervals on the first surface.