Modular Axial Flux Motor Segments for Automated Manufacturing
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Solution Overview
Problem
Current manufacturing techniques for axial flux motors are difficult to automate, leading to quality defects in core and motor construction.
Innovation Solution
A modular design for axial flux motors featuring a rotor and stator formed from individual wedge or bridge segments, allowing for simplified manufacturing processes and the use of various materials, including mixed materials, rare earth containing, and rare earth free designs with high power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing techniques are used for axial flux motors, then manufacturing complexity and automation difficulty increase, but manufacturing precision and quality may be maintained through manual control
Solution Approach 1:
The motor components (stator and rotor) are divided into multiple individual wedge segments that can be manufactured separately and assembled. This segmentation enables automated manufacturing of standardized components while maintaining high assembly precision through controlled joining processes. The wedge segments can be produced using automated cutting and forming operations, then precisely positioned and secured in the assembled motor structure.
2Ease of manufacture
If modular wedge segment design is implemented, then manufacturing simplicity and automation improve, but device complexity increases due to multiple components
Solution Approach 1:
The wedge segment design serves multiple functions simultaneously: it provides the magnetic core structure, defines the motor's geometric shape, creates the necessary air gaps for magnetic flux, and facilitates automated assembly through standardized interfaces. This multi-functionality reduces the need for separate components, thereby simplifying the overall device despite the modular approach.
Solution Approach 2:
Multiple functional elements are merged into the wedge segment structure itself. The segments combine the magnetic circuit, mechanical support, and geometric positioning functions into a single integrated component. This merging reduces the total number of separate parts needed in the motor construction.
3Power
If diverse materials including mixed and rare earth materials are used, then power density and magnetic performance improve, but manufacturing complexity and material handling difficulty increase
Solution Approach 1:
Different materials are strategically assigned to specific regions and components based on their functional requirements. Rare earth permanent magnets are used in the rotor where high magnetic field strength is critical, while alternative materials are used in the stator or non-critical areas. This localized material selection optimizes power density while managing manufacturing complexity by limiting the use of difficult-to-process materials to only where necessary.
Solution Approach 2:
The motor construction utilizes composite material approaches, combining different magnetic materials, structural materials, and bonding materials in a coordinated manner. The wedge segments themselves may be composite structures combining magnetic composites with structural materials, and the assembly uses composite joining methods (mechanical fastening, adhesive bonding, or interference fits) to unite the various material components.
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
The modular design simplifies manufacturing, reduces waste, and enhances mechanical and magnetic performance by enabling the use of diverse materials, resulting in improved power density and reduced production complexity.
Implementation Method 1
a rotor assembly having a plurality of rotor segments; a stator assembly having a plurality of stator segments
Implementation Method 2
The stator is positioned proximate to the rotor. The rotor, the stator, or both are formed of a plurality of individual wedge segments
Data Source
AI summary
An axial flux motor with a modular design that can help to simplify manufacturing processes, The design also permits the use of various material types, such as mixed materials, rare earth containing, and rare earth free designs with high power density. The motor may include a rotor arranged in one or more rings and a stator arranged in one or more rings. The stator is positioned proximate to the rotor. The rotor, the stator, or both are formed of individual wedge segments to provide a modular design. The rotor and/or stator assemblies may include a structural bearing material mixed with magnetic materials.