Interior Permanent Magnet Rotor Magnetizing Device
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Solution Overview
Problem
Existing methods for manufacturing interior permanent magnet (IPM) rotor units face challenges in applying a magnetic field in the radial direction to magnet materials within the core without expanding the core radially, as the magnetizing part must be strong enough to prevent radial expansion, which is difficult to achieve.
Innovation Solution
A method using a magnetizing device with an axial magnetizing part and a radial magnetizing part, where the radial magnetizing part is formed by alternately arranging low and high magnetic permeability portions, allowing the magnetic field to be applied radially through the radial part without needing to dispose the magnetizing source outside the core, thereby preventing radial expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the magnetizing part is disposed radially outside the core to apply magnetic field to magnet materials, then the magnet materials can be magnetized in radial direction, but the core expands radially outward due to insufficient strength of magnetizing part
Solution Approach 1:
The radial magnetizing part is segmented into alternating high magnetic permeability portions and low magnetic permeability portions in the circumferential direction. This segmentation allows the magnetic field to be applied effectively to the magnet materials while the low permeability portions prevent radial expansion of the core by acting as magnetic barriers.
Solution Approach 2:
Different portions of the radial magnetizing part have different magnetic permeability properties. The high permeability portions facilitate magnetic flux penetration to magnetize the magnet materials, while the low permeability portions provide structural support to prevent core expansion. This local differentiation of properties resolves the contradiction between magnetization effectiveness and shape stability.
2Shape
If the magnetizing part is made strong enough to prevent core from expanding radially outward, then the core shape stability is maintained, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Instead of increasing the mechanical strength of the magnetizing part, the invention changes the magnetic permeability parameter of different portions. By alternating high and low permeability portions in the circumferential direction, the system achieves both core shape stability and effective magnetization without requiring excessive mechanical strength, thereby reducing device complexity.
3Device complexity
If the radial magnetizing part uses uniform magnetic permeability, then the structure is simple, but the magnetic field cannot be effectively applied to magnet materials while preventing core expansion
Solution Approach 1:
The radial magnetizing part is divided into multiple segments with alternating high and low magnetic permeability in the circumferential direction. This segmentation creates a pattern where magnetic flux can penetrate through high permeability portions to magnetize the magnet materials, while low permeability portions prevent flux leakage and core expansion, achieving both structural simplicity and magnetization effectiveness.
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 approach enables effective magnetization of the magnet materials in the radial direction within the core, increasing the magnetization and orientation rates, which enhances the performance of the IPM rotor unit by improving the torque generated by the IPMSM when a current is applied.
Implementation Method 1
an axial magnetizing part serving as a source of a magnetic field... the axial magnetizing part applies the magnetic field toward the radial magnetizing part to apply the magnetic field to the magnet materials via the radial magnetizing part
Implementation Method 2
The radial magnetizing part is formed by alternately arranging low magnetic permeability portions and high magnetic permeability portions having higher magnetic permeability than the low magnetic permeability portions in a circumferential direction of the radial magnetizing part
Data Source
AI summary
In a method for manufacturing an interior permanent magnet rotor unit, a radial magnetizing part including high magnetic permeability portions and low magnetic permeability portions face a core, and a magnetic field of axial magnetizing parts is applied to the radial magnetizing part in an axial direction of the radial magnetizing part. This causes the magnetic field to enter the core via the radial magnetizing part and cross magnet materials filling insertion holes of the core.