Inserted Permanent Magnet Rotor Segmented Assembly
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Solution Overview
Problem
The challenge lies in integrating inserted permanent magnets (IPM) into external rotor electric machines effectively, as conventional methods struggle to optimize magnet placement and alignment within the rotor's structure for enhanced performance.
Innovation Solution
The solution involves a ring-shaped magnet receiving assembly with cylindrically shaped laminations and permanent magnets secured to the rotor's inner wall, utilizing adhesive or mechanical fastening, and strategically designed segments to create magnet-receiving portions, which allows for efficient magnet placement and alignment, improving the electric machine's efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional magnet placement methods are used in external rotor electric machines, then the rotor structure is simple, but magnet alignment and placement optimization cannot be achieved
Solution Approach 1:
The rotor structure is segmented into multiple functional components: a rotor core with recesses, magnet receiving assemblies with laminations, and permanent magnets. This segmentation allows each component to be optimized independently for precise magnet placement while maintaining overall rotor functionality.
Solution Approach 2:
A magnet receiving assembly acts as an intermediary component between the rotor core and permanent magnets. This assembly includes laminations that provide precise positioning features and recesses that guide magnet placement, thereby achieving manufacturing precision without directly modifying the rotor core structure.
2Object-generated harmful factors
If permanent magnets are directly mounted to the rotor, then the structure is simple, but magnetic field distribution and cogging torque cannot be optimized
Solution Approach 1:
The magnet receiving assembly incorporates laminations with specific local geometries including recesses, protrusions, and positioning features tailored to each magnet's location. This local quality optimization allows precise control of magnetic field distribution and cogging torque reduction at specific rotor positions.
Solution Approach 2:
The magnet receiving assembly is pre-configured with laminations and recesses before magnet installation. This preliminary action ensures that magnets are automatically positioned correctly during assembly, optimizing magnetic field distribution and minimizing cogging torque from the outset.
3Productivity
If IPM technology is integrated into external rotor machines, then machine efficiency is improved, but manufacturing and assembly difficulty increases
Solution Approach 1:
The IPM integration is achieved through segmented magnet receiving assemblies that can be manufactured separately and then assembled to the rotor core. This segmentation simplifies manufacturing by allowing specialized components to be produced using optimized processes and reduces assembly complexity through modular design.
Solution Approach 2:
The magnet receiving assembly incorporates self-aligning features such as recesses, protrusions, and geometric constraints that enable automatic positioning during assembly. This self-service mechanism reduces the skill level and time required for assembly while ensuring precise magnet placement for optimal efficiency.
Data Source
AI summary
The external rotor for an electric machine includes a cylindrically shaped receptacle having a peripheral wall and a magnet-receiving assembly including segments assembled to the inner surface of the peripheral wall so as to define a cylindrically shaped stack. The segments are shaped so as to yield magnet-receiving portions in the ring-shaped stack, and permanent magnets are secured to the magnet-receiving portion of the magnet receiving assembly.