Wire Arc Additive Manufactured Magnetic Elevator Drive Member
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Solution Overview
Problem
Implementing rotary magnetic drive arrangements for elevator systems on a commercial scale is challenging due to high material and manufacturing costs, and ensuring efficient and reliable operation of the components.
Innovation Solution
A method using wire arc additive manufacturing to create a magnetic drive member with low carbon steel magnet retainers and rare earth magnets arranged in a helical configuration on a hollow cylinder rod, with dovetail cross-sections to concentrate magnetic flux and maintain magnet position, eliminating the need for additional retention materials like carbon fiber wraps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rotary magnetic drive arrangements are implemented, then elevator propulsion function is achieved, but material and manufacturing costs become prohibitively expensive
Solution Approach 1:
The magnetic drive member is segmented into discrete permanent magnets arranged in alternating polarity patterns around the rotor. This segmentation allows for more efficient magnetic flux distribution and reduced material usage compared to continuous magnetic structures, thereby lowering manufacturing costs while maintaining propulsion reliability
Solution Approach 2:
The invention changes the magnetic field configuration parameters by using alternating polarity arrangements and specific magnet spacing. This optimization improves magnetic efficiency and reduces the total amount of magnetic material required, addressing the cost issue while preserving the elevator propulsion function
2Reliability
If magnetic drive components are arranged to ensure efficient operation, then propulsion reliability is improved, but device complexity increases
Solution Approach 1:
The rotor structure serves multiple functions simultaneously: it provides mechanical support for the magnets, establishes the magnetic field configuration, and acts as the rotating propulsion element. This multi-functionality reduces the number of separate components needed, simplifying the overall device while maintaining efficient propulsion operation
Solution Approach 2:
The invention merges the magnetic field generation function with the mechanical rotor structure by directly mounting permanent magnets to the rotor body. This integration eliminates separate magnetic field generation components and simplifies the overall device architecture while ensuring efficient and reliable propulsion
3Reliability
If magnet retainers are shaped with retention features, then magnet positioning reliability is improved, but manufacturing steps increase
Solution Approach 1:
Retention features such as recesses or keyways are pre-formed in the rotor or magnet retainers during the initial manufacturing process. This preliminary action ensures accurate magnet positioning is built into the structure from the start, improving positioning reliability while avoiding the need for additional complex assembly steps
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 approach results in a cost-effective, efficient, and reliable magnetic drive system that reduces material costs and space requirements while providing sufficient driving force for elevator propulsion, with improved magnetic efficiency and reduced iron losses.
Implementation Method 1
the additive manufacturing process comprises wire arc additive manufacturing
Implementation Method 2
dovetail cross-sections to concentrate magnetic flux
Implementation Method 3
A magnetic drive arrangement includes a magnetic drive member and a stationary magnetic drive member
Data Source
Figure 1~3
Figure 4~6
AI summary
An illustrative example embodiment of a method of making a rotary magnetic drive member includes establishing a plurality of magnet retainers (42, 44) on a rod (40) using an additive manufacturing process. Magnets (46A, 46B, 46C) are inserted between the retainers (42, 44) with magnetic poles of axially adjacent ones of the magnets (46A, 46B, 46C) oriented with like poles facing toward a portion of one of the retainers (42, 44) between the adjacent ones of the magnets (46A, 46B, 46C).