Motor Magnet Clip Assembly for In-Flight Stability
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Solution Overview
Problem
Magnets inside electric motors can fall or malfunction during flight, leading to catastrophic damage to aircraft and personnel, highlighting the need for effective motor component assembly and stabilization techniques.
Innovation Solution
A method involving a clip system where magnets are stacked on a vertical dowel hoop, compressed by top and bottom plates, and cured to secure their position, utilizing a vertical dowel hoop with dowels to hold magnets in place and applying adhesive between them for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnets are stacked on vertical dowel hoop without compression, then assembly is simple, but magnets may fall or malfunction during flight
Solution Approach 1:
The patent applies preliminary action by compressing the magnets between plates before the adhesive cures. This pre-compression ensures the magnets are held securely in position during the curing process and continues to prevent magnet movement during flight operation, resolving the contradiction between simple assembly and flight reliability.
Solution Approach 2:
The patent introduces plates as an intermediary element between the magnets and the external environment. These plates apply continuous compression force to the magnets stacked on the vertical dowel hoop, preventing them from falling or malfunctioning during flight while maintaining simple assembly through the dowel-hoop structure.
2Manufacturing precision
If magnets are compressed between plates, then magnet positioning stability is improved, but manufacturing process complexity increases
Solution Approach 1:
The vertical dowel hoop serves multiple functions: it provides the structural framework for stacking magnets, acts as a positioning guide, and works with the plates to apply compression. This multi-functionality reduces the need for additional specialized components, thereby improving magnet positioning accuracy without proportionally increasing device complexity.
Solution Approach 2:
The patent employs a nested structure where magnets are stacked on the vertical dowel hoop, which is itself nested within the compression system formed by the plates. This nested arrangement achieves precise magnet positioning through the dowel's guidance while the plates provide uniform compression, balancing positioning accuracy with structural efficiency.
3Reliability
If adhesive is applied between magnets, then magnet stability is improved, but curing time increases
Solution Approach 1:
The patent applies preliminary mechanical compression through the plates before the adhesive curing process completes. This pre-compression stabilizes the magnets during curing, allowing the adhesive to bond effectively without requiring extended curing time, thus improving assembly stability while minimizing time loss.
Solution Approach 2:
The patent merges mechanical compression (through plates) with chemical bonding (adhesive curing) into a single integrated process. The compression force is applied concurrently with the curing process, allowing both mechanisms to work together to stabilize the magnets, thereby reducing the total time required compared to using adhesive alone.
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 method ensures the secure positioning and stability of magnets within the motor, preventing malfunctions and ensuring the safety and reliability of electric aircraft by maintaining magnet alignment and compression during the manufacturing process.
Implementation Method 1
applying adhesive between them for stability
Data Source
AI summary
A method for motor manufacturing using a clip system is illustrated. The method includes sliding a plurality of magnets onto a vertical dowel hoop, wherein the plurality of magnets are stacked on each dowel, attaching a first plate to the top of the vertical dowel hoop and a second plate to the bottom of the vertical dowel hoop, wherein the plates compress the plurality of magnets on each vertical dowel, and curing the combination of the first plate, the second plate, the plurality of magnets and the vertical dowel hoop.