Modular Rotor Design for High-Speed PMSM Torque
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Solution Overview
Problem
The scarcity of rare earth resources used in permanent magnet synchronous motors (PMSMs) leads to high costs and fluctuating prices, necessitating alternatives or technologies that can replicate their performance without using rare earth resources.
Innovation Solution
A rotor design featuring a rotor core with modules comprising pairs of permanent magnets and connection parts, including non-magnetic materials or air, to enhance magnetic flux and torque, allowing for efficient high-power operation at high driving speeds without relying on rare earth magnets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rare earth resource magnets (NdFeB) are used to achieve high residual magnetism and coercive force, then motor performance is improved, but cost increases and cost fluctuations occur due to resource scarcity
Solution Approach 1:
The patent replaces expensive rare earth magnets with non-rare earth permanent magnets that are cheaper and more readily available. The design uses alternative magnetic materials that do not depend on scarce rare earth resources, thereby reducing manufacturing cost while maintaining functional performance requirements.
Solution Approach 2:
The patent employs composite magnetic structures combining different permanent magnet materials arranged in specific patterns (alternating polarity arrangements) to achieve the required magnetic performance without relying on rare earth resources. This composite approach allows optimization of magnetic properties using available non-rare earth materials.
2Power
If conventional rotor designs are used, then manufacturing is simpler, but high-power operation at high driving speeds cannot be achieved
Solution Approach 1:
The rotor is divided into multiple modular units, each containing permanent magnets with specific polarities. These modules are arranged in an alternating polarity pattern around the rotor circumference, creating a segmented magnetic structure that enhances flux distribution and enables high-power operation at high speeds while maintaining manufacturability through modular assembly.
Solution Approach 2:
The patent introduces a radial dimension to the magnetic flux path by arranging permanent magnets in alternating polarities around the rotor circumference. This creates a multi-dimensional magnetic flux distribution pattern that increases the effective magnetic interaction with the stator, enabling high-power operation without simply increasing magnet size or quantity in a single dimension.
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 design increases reluctance torque, enabling high-power operation at high driving speeds while reducing the reliance on rare earth magnets, thus addressing cost and availability issues.
Implementation Method 1
a motor comprising a rotor, a shaft and a stator. The rotor includes a rotor core, which is formed at a center thereof with a hole coupled to a shaft. The rotor also includes a module, which is coupled to the rotor core
Implementation Method 2
The module comprises a pair of first permanent magnets spaced apart from each other and a first connection part connecting ends of the first permanent magnets to each other
Data Source
AI summary
A rotor and a motor are provided in which the q-axis inductance is increased and the leakage of magnetic flux is prevented to ensure high power operation at high level driving speeds. The rotor includes a rotor core, which is formed at the center thereof with a hole coupled to a shaft, and a module configured to be coupled to the rotor core and comprises a pair of first permanent magnets, which are space apart from each other, and a first connection part connecting ends of the first permanent magnets to each other.