Permanent Magnet Work Face Transition Edge Design
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Solution Overview
Problem
Rare earth embedded permanent magnets have low flux utilization coefficients and high costs due to their square shape, and irregular shapes to improve this result in poor mechanical strength and manufacturability.
Innovation Solution
A permanent magnet design with a work face featuring perpendicular edges connected by a transition edge that includes sub-arc and sub-straight segments, optimizing the shape to enhance mechanical strength and manufacturability while reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the work face of the permanent magnet is made into an irregular shape to reduce material cost and increase flux utilization, then the coefficient of flux utilization is improved and material cost is reduced, but the mechanical strength and manufacturability deteriorate
Solution Approach 1:
The patent applies curvature by introducing arc segments (first arc segment and second arc segment) to connect the straight edges of the work face. These curved transition regions replace sharp corners with smooth arcs, which significantly improve mechanical strength by eliminating stress concentration points while maintaining the irregular shape that reduces material usage. The arc segments create a more favorable stress distribution pattern throughout the permanent magnet structure.
Solution Approach 2:
The patent employs parameter changes by carefully controlling the geometric parameters of the transition edges, including the radius of the arc segments and the angles of connection. By optimizing these parameters, the design achieves a balance between material efficiency (irregular shape) and mechanical integrity (smooth transitions). The specific parameter ranges for arc radii and connection angles are designed to maximize both flux utilization and structural strength.
2Quantity of substance
If the work face of the permanent magnet is made into an irregular shape to reduce material cost, then the cost performance is improved, but the manufacturability deteriorates
Solution Approach 1:
The curved arc segments in the transition edges simplify manufacturing by eliminating sharp corners that are difficult to produce and prone to defects. The smooth curved transitions are easier to form using conventional manufacturing processes such as injection molding or die pressing, thereby improving manufacturability while maintaining the material-saving irregular shape.
Solution Approach 2:
By optimizing the geometric parameters of the transition edges (arc radii, connection angles), the patent creates a design that is both material-efficient and manufacturable. The parameter optimization ensures that the irregular shape can be produced with high precision using standard manufacturing processes, improving the qualification rate and reducing production complexity.
3Ease of manufacture
If a square work face is used for the permanent magnet, then the manufacturability is good, but the coefficient of flux utilization is low and material cost is high
Solution Approach 1:
The patent introduces asymmetry by designing an irregular work face shape that is optimized for flux utilization. The asymmetric arrangement of edges and transition regions allows better alignment with the magnetic flux distribution patterns, reducing wasted material while maintaining manufacturability through the use of symmetric arc segments in the transitions.
4Quantity of substance
If an irregular shape is used for the permanent magnet work face, then the coefficient of flux utilization is improved, but the mechanical strength character deteriorates
Solution Approach 1:
The arc segments in the transition edges serve as stress-relieving features that maintain mechanical strength while enabling the irregular shape. The curved geometry distributes mechanical stresses more evenly throughout the permanent magnet, preventing stress concentration at corners and improving overall structural integrity despite the non-square configuration.
Data Source
AI summary
A permanent magnet, a rotor, a motor and a compressor are provided. A work face of the permanent magnet includes a first edge and a second edge, a head endpoint of the first edge is connected to a tail endpoint of the second edge by means of a transition edge, the transition edge is located at a side, adjacent to a center of the work face, of a line connecting the head endpoint with the tail endpoint, and the transition edge includes at least one sub-arc segment, or a combination of at least one sub-arc segment and at least one sub-straight segment.