Layered Rotor Core Reinforcement for High-Speed Magnetic Stability
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Solution Overview
Problem
Magnet-embedded rotating electric machines face challenges in maintaining strength and stability at high speeds due to the weight and centrifugal forces acting on the rotor, which can lead to reduced performance and increased risk of magnetic flux short circuits.
Innovation Solution
The rotor design incorporates a reinforcement part with a resin material and center ribs, along with a compression part that applies a load to the rotor core, and uses arc-shaped magnets to reduce thickness and prevent crushing, while maintaining magnetic field integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If magnets are inserted into magnet insertion holes forming multiple layers in radial direction to increase rotation speed, then productivity and performance are improved, but rotor weight increases and centrifugal force increases reducing reliability
Solution Approach 1:
The rotor core is divided into multiple radial layers with magnet insertion holes at different depths, allowing magnets to be segmented and inserted into specific radial positions. This segmentation enables optimized weight distribution and reduced centrifugal stress while maintaining high rotation speed capability
Solution Approach 2:
The rotor core uses composite construction combining magnetic materials with non-magnetic reinforcement materials in specific patterns, creating a structure that reduces weight while maintaining or enhancing mechanical strength to withstand centrifugal forces at high rotation speeds
2Reliability
If rotor weight is reduced to decrease centrifugal force, then reliability is improved, but strength may be compromised
Solution Approach 1:
Different regions of the rotor core have different material properties and structural characteristics - outer regions use lighter materials while inner regions and critical stress areas use stronger materials, optimizing the balance between weight reduction and strength maintenance
Solution Approach 2:
The rotor core employs curved and arc-shaped structural elements rather than straight lines, distributing stress more evenly across the rotor structure and improving resistance to centrifugal forces while maintaining reduced weight
3Power
If magnets are press-fitted into magnet insertion holes, then magnetic field strength is improved, but manufacturing complexity increases
Solution Approach 1:
Magnet insertion holes are pre-formed with precise dimensions and positioning during rotor core manufacturing, and magnets are pre-assembled in correct orientations before final assembly. This preliminary preparation simplifies the overall manufacturing process while ensuring optimal magnetic field generation
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 configuration enhances the rotor's strength and stability at high speeds, reduces weight, and minimizes magnetic flux leakage, allowing for efficient and reliable operation.
Implementation Method 1
a compression part configured to apply a load to the rotor core from an outward side in the radial direction toward an inward side in the radial direction
Implementation Method 2
a magnet press-fitted into the magnet insertion hole
Data Source
AI summary
A rotor of the present invention includes a rotor core in which a shaft through-hole and a magnet insertion hole that form a plurality of layers in a radial direction toward a central axis of the shaft through-hole are formed, and a magnet press-fitted into the magnet insertion hole, and the rotor core includes a reinforcement part between the shaft through-hole and a first magnet insertion hole disposed on outermost side in the radial direction.