IPM Rotor Magnet Slot Structure for Stable Pressing Force
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Solution Overview
Problem
The existing IPM rotor technology faces challenges in maintaining a stable pressing force on magnets due to the reliance on the length of the flat spring portion for adjustment, leading to variability in the pressing force.
Innovation Solution
The IPM rotor design incorporates a rotor core with a first and second core sheet, where the first sheet hole features a flat spring portion that bends upon magnet insertion, and the second sheet hole has a concave portion allowing the flat spring to escape, with clearance sizes set to stabilize the pressing force based on its magnitude and variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pressing force is adjusted based only on the length of the flat spring portion, then the adjustment is simple, but the pressing force stability deteriorates
Solution Approach 1:
The invention divides the pressing force adjustment mechanism into multiple independent parameters: clearance size between the flat spring portion and magnet, and flat spring portion length. This segmentation allows each parameter to be optimized independently, with clearance controlling the magnitude of pressing force and spring length controlling the stability, thereby resolving the contradiction between simple adjustment and stable pressing force.
Solution Approach 2:
The invention changes the adjustment parameters from solely spring length to a combination of clearance size and spring length. By controlling the clearance size between the flat spring portion and magnet, the pressing force magnitude is regulated, while the spring length ensures stable elastic deformation, achieving both adjustable and stable pressing force.
2Force
If the flat spring portion is made longer to increase pressing force, then the pressing force magnitude increases, but the variation in pressing force increases
Solution Approach 1:
The invention separates the control of pressing force magnitude from pressing force stability by introducing clearance size as an independent parameter. The clearance controls the magnitude through the elastic deformation range, while the flat spring portion length controls the stability through consistent material properties, preventing the trade-off between force magnitude and consistency.
Solution Approach 2:
The clearance acts as an intermediary element between the flat spring portion and the magnet. It mediates the force transmission by controlling the elastic deformation range, allowing the spring to exert consistent pressing force while the clearance ensures stable magnitude, thereby reducing variation in pressing force.
3Reliability
If the clearance size is reduced to stabilize pressing force, then the pressing force stability improves, but the magnet insertion difficulty increases
Solution Approach 1:
The invention optimizes the clearance size parameter to achieve a balance between stability and insertability. The clearance is designed to be small enough to ensure stable pressing force during operation but large enough to allow smooth magnet insertion, resolving the contradiction between these two requirements through precise parameter control.
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 effectively stabilizes the pressing force on the magnet, reducing torque reduction and magnetic field interruption while ensuring consistent magnet retention.
Implementation Method 1
the flat spring portion is bent by the magnet through insertion of the magnet into the accommodation hole
Data Source
AI summary
In an IPM rotor, a first core sheet has a first sheet hole forming a part of an accommodation hole. The first sheet hole has an edge portion having a flat spring portion which is bent by a magnet through insertion of the magnet into the accommodation hole. A pair of recesses forming a clearance with respect to the magnet are formed at both side portions of the flat spring portion of the edge portion of the first sheet hole. A size of the clearance is set based on a relationship between a magnitude of a pressing force of the flat spring portion on the magnet and variation in pressing force.