Permanent Magnet Rotor Tongue Locking to Reduce Micromovement
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Solution Overview
Problem
Current methods for securing permanent magnets in rotary electric machines, such as adhesive bonding and impregnation, are costly, complex, and can lead to magnetic performance losses due to clearance issues and micromovements, which affect the machine's efficiency and durability.
Innovation Solution
A rotor design featuring a deformable tongue in the rotor body that bends to press against the small side of the permanent magnet, mechanically locking it in place without the need for adhesives, thereby minimizing micromovements and magnetic losses, and allowing for better magnetic flux flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding is used to secure magnets in recesses, then magnets are locked in place, but the process becomes lengthy and complex requiring heating and cooling operations
Solution Approach 1:
The invention extracts the magnet from the recess after insertion, eliminating the need for adhesive bonding. The magnet is temporarily held during insertion but then removed, allowing the recess to be filled with adhesive that bonds the magnet to the rotor body without requiring complex heating and cooling operations.
Solution Approach 2:
The invention performs preliminary insertion of the magnet into the recess before final bonding. The magnet is first inserted and held in position, then the adhesive is applied, and finally the magnet is secured. This preliminary action allows for proper adhesive distribution and bonding without requiring complex equipment.
2Reliability
If adhesive bonding is used to secure magnets, then magnets are locked in place, but leakage occurs affecting cleanliness and production complexity
Solution Approach 1:
The magnet is extracted from the recess after insertion but before final bonding. This extraction allows the adhesive to be properly applied and distributed in the recess without the magnet interfering, preventing leakage and ensuring clean bonding without affecting production complexity.
3Reliability
If magnets with specific shapes are used to improve securing, then magnet retention is enhanced, but production cost significantly increases
Solution Approach 1:
The invention uses the magnet's own geometric features (protrusions or recesses) to engage with corresponding features in the rotor body, allowing the magnet to self-secure without requiring complex external retention mechanisms. This self-service approach maintains reliability while using standard magnet shapes for cost-effective production.
4Ease of operation
If clearance is maintained between magnets and recesses for mounting ease, then magnet insertion is facilitated, but magnetic performance is reduced due to air gap losses
Solution Approach 1:
The invention changes the dimensional parameters of the magnet and recess to achieve optimal fit. The magnet is designed with dimensions that allow minimal clearance for easy insertion while maintaining sufficient contact area to minimize air gap losses and maximize magnetic flux flow between the magnet and rotor body.
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 solution enhances the magnetic performance and reduces manufacturing costs by securely locking the magnets in place, minimizing micromovements and noise, while maintaining optimal magnetic flux flow.
Implementation Method 1
at least one sheet including at least one deformable tongue connecting to said face of the recess and extending into the recess, the deformable tongue being angled and including a bendable portion that is configured to press against the small side of the permanent magnet
Data Source
AI summary
Rotor (30) for a rotary electric machine, including:at least one permanent magnet (1) having, in cross section, at least one large side (2a) and at least one small side (3a),a rotor body (33) including stacked sheets, the rotor body (33) including at least one recess (4) receiving the permanent magnet (1), the recess (4) being delimited by at least one face (5a) opposite the large side (2a) of the permanent magnet (1),at least one sheet (6) including at least one deformable tongue (7) connecting to the face (5a) of the recess (4) and extending into the recess (4), the deformable tongue (7) being angled and including a foldable portion (8) configured to be pressed against the small side (3a) of the permanent magnet (1).