Magnet Tiles Assembly with Male-Female Interface
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Solution Overview
Problem
Existing magnet assemblies for brushless direct current motors face issues with magnet displacement during manufacturing, leading to dimensional spreads, balancing problems, and magnetic field imbalances due to permanent magnetic forces, and previous solutions like magnets in slots result in significant magnetic force loss and size incompatibility.
Innovation Solution
A rotor with a support member featuring male and female portions on its surface allows for precise positioning of magnets, engaging them securely to prevent displacement during assembly, utilizing a polygonal cross-section for optimal magnetic field symmetry and attachment, even in small sizes where traditional methods fail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnets are attached directly onto the shaft using traditional methods, then the assembly process is simple, but magnet displacement occurs during manufacturing due to permanent magnetic forces
Solution Approach 1:
The support member is segmented into multiple portions, each with dedicated male and female portions for individual magnet engagement. This segmentation allows each magnet to be independently positioned and secured, preventing displacement while maintaining assembly simplicity.
Solution Approach 2:
Male and female portions act as intermediary mechanical features between the magnets and support member. These intermediaries provide precise positioning and secure engagement, eliminating direct magnet-to-shaft attachment issues while preserving manufacturing ease.
2Manufacturing precision
If magnets are positioned in slots of the rotor, then magnet positioning is improved, but significant magnetic force is lost and size reduction is incompatible
Solution Approach 1:
The support member features a polygonal cross-section that dynamically engages with the magnets through male and female portions. This dynamic engagement allows precise positioning without rigid slot constraints, maintaining magnetic force while enabling size reduction.
Solution Approach 2:
Instead of confining magnets to slot-based two-dimensional positioning, the invention uses three-dimensional male-female portion engagement on the polygonal support member surface. This dimensional approach provides precise positioning without the magnetic force losses associated with slot configurations.
3Productivity
If magnets are attached without mechanical positioning features, then the assembly process is fast, but dimensional spreads and balancing issues occur
Solution Approach 1:
The male and female portions are pre-formed on the support member before magnet attachment. This preliminary action ensures that when magnets are attached, they are automatically positioned with high precision, achieving both fast assembly and dimensional consistency without requiring post-assembly adjustments.
4Manufacturing precision
If the support member uses a polygonal cross-section with male and female portions, then magnet positioning precision is improved, but device complexity increases
Solution Approach 1:
The polygonal support member structure serves multiple functions simultaneously: it provides mechanical strength, defines precise magnet positions through its geometry, and creates the male-female engagement features. This multi-functionality reduces overall device complexity while maintaining high positioning precision.
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 ensures accurate magnet placement, reducing displacement and maintaining magnetic field symmetry, even in small motors where traditional attachment methods are difficult, thereby enhancing motor performance and reliability.
Implementation Method 1
one of the said outer surface of said support member and each of the said plurality of magnets comprises at least one male portion, the other of the said outer surface of said support member and each of the said plurality of magnets comprises at least one female portion, and in that the at least one male portion is engaged into the at least one female portion
Implementation Method 2
due to the permanent magnetic forces, movements of the magnets may occur during the steps of manufacturing
Data Source
Figure 1a~1b
Figure 2~3
Figure 4
AI summary
Magnet assembly comprising: - at least one support member, - a plurality of magnets, wherein each one of the plurality of magnets is positioned relatively to the at least one support member by a male-female interface. For each one of the plurality of magnets, a male portion is engaged into a female portion so that displacements during a step of attachment of each one of the plurality of magnets to the at least one support member are avoided.