Magnet Rotor Assembly With Deformable End Rings for Partial Grinding
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Solution Overview
Problem
The manufacturing process of magnet rotor assemblies with low energy magnets is resource-intensive due to the need to fully grind the ends of these magnets to match the rotor core surfaces, leading to inefficiencies.
Innovation Solution
Incorporation of deformable end rings with specific deformable areas to accommodate magnets of varying lengths, allowing for partial grinding and improved retention within the rotor core, using materials like metallic rings with cuts, cantilevered beams, or closed cell foam caps to facilitate deformation and secure the magnets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the ends of low energy magnets are fully ground to match the rotor core surfaces, then the manufacturing precision is improved, but the resource consumption increases significantly
Solution Approach 1:
The end ring is designed with differentiated local properties: rigid portions maintain structural integrity and precise positioning, while deformable portions accommodate magnet length variations without requiring full grinding of all magnets. This localized quality differentiation allows partial grinding of low energy magnets while maintaining assembly precision.
Solution Approach 2:
The end ring incorporates deformable portions that can dynamically adjust to accommodate magnets of varying lengths. This dynamic capability eliminates the need for static full-grinding of all magnets, reducing material removal while maintaining precise fit and retention.
2Loss of substance
If deformable end rings are used to accommodate varying magnet lengths, then the resource consumption is reduced, but the device complexity increases
Solution Approach 1:
The end ring is segmented into distinct rigid and deformable portions, each performing specific functions. This segmentation allows the structure to achieve complexity only where necessary (deformable regions) while maintaining simplicity in other areas (rigid regions), balancing functionality with manufacturing feasibility.
Solution Approach 2:
The end ring employs composite construction combining rigid and deformable materials or structures within a single component. This composite approach enables the end ring to simultaneously provide structural support and accommodation for magnet length variations, reducing the need for additional separate components.
3Productivity
If partially ground magnets are used with deformable end rings, then the productivity is improved, but the retention reliability may be compromised
Solution Approach 1:
The rigid portions of the end ring provide counterbalancing structural support that compensates for the reduced retention capability of deformable portions. This counterweight effect ensures that overall magnet retention reliability is maintained even when magnets are only partially ground to fit deformable areas.
Solution Approach 2:
The deformable portions act as intermediaries between magnets of varying lengths and the rigid end ring structure. These deformable intermediaries accommodate length variations while the rigid portions provide ultimate retention, ensuring both productivity improvement and reliability maintenance.
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 design reduces resource consumption by allowing partial grinding, enhances magnet retention, and maintains operational efficiency in magnet rotor assemblies.
Implementation Method 1
a first partially ground magnet of the plurality of partially ground magnets has an associated magnet length that is greater than the rotor core length and a first partially ground magnet end of the first partially ground magnet abuts against a first deformable area of the plurality of first deformable areas of the first deformable end ring causing a deformation of the first deformable area of the first deformable end ring
Data Source
AI summary
A magnet rotor assembly includes a rotor core having a rotor core length along a longitudinal axis. A plurality of partially ground magnets are disposed at partially ground magnet locations within the rotor core, have a magnet length extending along the longitudinal axis, a first partially ground magnet end, and a second partially ground magnet end. A deformable end ring is disposed at an end of the rotor core to retain the partially ground magnets within the rotor core. The deformable end ring includes a plurality of deformable areas. Each of the deformable areas corresponds to a partially ground magnet location. A partially ground magnet has an associated magnet length that is greater than the rotor core length and a partially ground magnet end of that partially ground magnet abuts against a first deformable area of the deformable end ring causing a deformation of the first deformable area.