Permanent Magnet Module Radial Holes for Conforming Contact
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Solution Overview
Problem
In permanent magnet rotors, non-uniform pressure during assembly leads to stress concentration and non-conforming contact between magnets and the base or central magnet support structure, causing vibrations and reduced magnetic flux.
Innovation Solution
The design of permanent magnet modules ensures conforming contact between magnets and the base or central magnet support structure by increasing the number of contact points through adaptations such as larger central magnet support structures, grooves, and elastic elements, which account for deformation during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolts are tightened to fix the central magnet structure to the base, then the permanent magnet structure is secured, but non-uniform pressure causes base deformation and stress concentration
Solution Approach 1:
The patent applies local quality by providing support structures (radial support structures and lateral support structures) at specific locations where stress concentration occurs. These support structures are strategically placed to provide localized reinforcement exactly where the base deformation and stress concentration problems occur during bolt tightening, rather than uniformly strengthening the entire base.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating radial support structures and lateral support structures that preemptively counteract the deformation forces before they can cause damage. These support structures are designed to absorb and distribute the non-uniform pressure from bolt tightening, preventing base deformation and stress concentration from developing in the first place.
2Reliability
If the base deforms under bolt pressure, then the permanent magnets may become detached, but this causes vibrations and reduced magnetic flux during operation
Solution Approach 1:
The patent uses local quality by placing lateral support structures specifically at the interfaces between permanent magnets and the base. These localized support structures ensure that the magnets remain firmly attached by providing additional bearing surfaces that prevent detachment, while also reducing vibrations by distributing the mechanical stresses locally rather than allowing them to propagate through the entire structure.
3Strength
If stress concentration points appear on the base, then the structural integrity is compromised, but this reduces the effectiveness of the flux concentrator
Solution Approach 1:
The patent applies local quality by positioning radial support structures at the stress concentration points on the base. These support structures locally reinforce the base geometry exactly where stress concentration occurs, maintaining structural integrity by preventing crack initiation and propagation. By preserving the base's structural integrity, the magnetic flux pathways remain uninterrupted, preventing energy loss in the magnetic circuit.
Data Source
AI summary
A permanent magnet rotor comprising a rotor rim and a plurality of permanent magnet modules arranged on the outer or inner circumference of the rotor rim. The permanent magnet modules comprise a base adapted to be fixed to the rotor rim, one or more permanent magnets, and a central magnet support structure. The base and the central magnet support structure comprise a plurality of radial holes. The permanent magnet modules are adapted so that, when bolts are inserted in the radial holes to fix the central magnet support structure to the base, at least a portion of a first and a second surface of each permanent magnet remain substantially in conforming contact with a surface of the base and a surface of the central magnet support structure, respectively.