Permanent Magnet Cut-Outs for Eddy Current Reduction
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Solution Overview
Problem
Existing methods for producing segmented permanent magnets for electric machines are complex and costly, as they require multiple steps of producing smaller parts and adhering them together.
Innovation Solution
A permanent magnet design featuring cut-outs that alternate from opposite sides, forming material bridges that keep the magnet as a single part, while minimizing eddy current losses through optimized cutting patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the magnet is segmented by producing smaller parts and adhering them together, then eddy current losses are minimized, but manufacturing complexity and costs increase significantly
Solution Approach 1:
The patent applies segmentation by creating through-cut grooves that divide the magnet into multiple portions while maintaining connectivity through bridges. This achieves eddy current minimization similar to classic segmentation but without the need to produce and adhere separate parts, thereby reducing manufacturing complexity.
Solution Approach 2:
The patent merges the segmentation function with the magnet body by integrating bridges that connect the segmented portions. This combination allows the magnet to function as a single integrated component rather than requiring assembly of separate parts, eliminating adherence steps and reducing manufacturing complexity.
2Loss of energy
If the magnet is segmented by producing smaller parts and adhering them together, then eddy current losses are minimized, but production costs increase significantly
Solution Approach 1:
The patent implements segmentation through grooves cut into the magnet body, creating portions separated by material bridges. This approach achieves the eddy current reduction benefits of segmentation while avoiding the costly multi-step process of producing and adhering separate parts.
Solution Approach 2:
The patent extracts only the essential segmentation function by removing material to create grooves, while retaining the magnet as a single integrated piece through bridges. This eliminates the need for expensive adherence processes while maintaining the energy loss reduction benefits.
3Loss of energy
If through-cuts are made to separate the magnet completely, then eddy current losses are minimized, but the magnet structure is compromised
Solution Approach 1:
The patent segments the magnet using grooves that do not completely separate the portions. The material bridges maintain structural connectivity, preserving magnet integrity while still achieving eddy current reduction through the segmented portions.
Solution Approach 2:
The material bridges act as intermediaries between the segmented portions, maintaining structural integrity and magnetic flux continuity while allowing the grooves to reduce eddy currents. The bridges mediate between the need for segmentation and the need for structural strength.
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 reduces complexity and costs by allowing for efficient production of segmented magnets with minimal eddy current losses, comparable to classic segmentation methods.
Implementation Method 1
The cut-outs are created via water jet cutting with corresponding fan nozzles.
Data Source
AI summary
A permanent magnet includes a magnetic base body that has a direction of magnetization and at least two recesses formed orthogonally to the direction of magnetization. The at least two recesses are formed as cut-outs and run substantially parallel to each another. A first cut-out is formed out of a first side of the base body such that no material bridge remains between the first cut-out and the first side and a second cut-out is formed out of a second side of the base body such that no material bridge remains between the second cut-out and the second side. The first and second cut-outs extend only partially along a width of the base body resulting in a first material bridge from the first cut-out to the second side and a second material bridge from the second cut-out to the first side. The first cut-out is spaced from the second cut-out.