Motor Rotor Assembly Pole Center Alignment
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Solution Overview
Problem
Conventional methods for aligning pole centers of permanent magnets in high-speed motors are prone to misalignment, increasing manufacturing time and cost, especially when using segment magnets, due to the need for complex machining and alignment patterns.
Innovation Solution
A motor rotor assembly that uses a rod with a reference guide to align pole centers through attractive and repulsive forces between disc-type magnet units, allowing for quick assembly and full magnetization after alignment, reducing the need for intricate machining and alignment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods with specific marks or patterns are used to align pole centers of segment magnets, then alignment accuracy may be improved, but manufacturing time and cost are increased
Solution Approach 1:
The patent replaces complex mechanical alignment methods (machining uneven patterns, forming alignment reference patterns) with a magnetic field-based alignment system. A magnetization device generates a magnetic field that automatically aligns the pole centers of segment magnets through magnetic interaction, eliminating the need for mechanical machining and pattern formation while achieving precise alignment.
Solution Approach 2:
The patent changes the magnetic field parameters during the alignment process. The magnetization device generates a controlled magnetic field with specific strength and direction that induces magnetic moments in the segment magnets, causing them to align their pole centers automatically. By controlling the magnetic field parameters, precise alignment is achieved without mechanical intervention.
2Manufacturing precision
If machining uneven patterns or alignment reference patterns is performed on magnets or rods, then pole center alignment can be achieved, but device complexity and manufacturing cost are increased
Solution Approach 1:
The patent replaces complex mechanical alignment methods (machining uneven patterns, forming alignment reference patterns) with a magnetic field-based alignment system. A magnetization device generates a magnetic field that automatically aligns the pole centers of segment magnets through magnetic interaction, eliminating the need for mechanical machining and pattern formation while achieving precise alignment.
Solution Approach 2:
The segment magnets align their own pole centers automatically through magnetic interaction with the magnetization device. The magnetic field induces magnetic moments in the segment magnets, causing them to self-align without requiring external mechanical guidance features or reference patterns. This self-alignment capability eliminates the need for complex machining operations.
3Ease of manufacture
If a single permanent magnet is used instead of segmented magnets, then assembly is simpler, but eddy current loss increases and manufacturing flexibility decreases
Solution Approach 1:
The patent divides the permanent magnet into multiple segment magnets arranged in a circular pattern. This segmentation reduces eddy current loss by breaking up continuous conductive paths that would otherwise allow large eddy currents to flow. The segment magnets can be independently manufactured and then assembled using the magnetic field alignment method, achieving both energy efficiency and manufacturing flexibility.
Solution Approach 2:
The patent replaces complex mechanical alignment methods (machining uneven patterns, forming alignment reference patterns) with a magnetic field-based alignment system. A magnetization device generates a magnetic field that automatically aligns the pole centers of segment magnets through magnetic interaction, eliminating the need for mechanical machining and pattern formation while achieving precise alignment.
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 significantly reduces manufacturing time and cost by simplifying the alignment process and ensuring accurate polarity alignment of magnet units, preventing misalignment issues during assembly.
Implementation Method 1
pole centers of the disc type magnet units adjacent to each other are aligned to each other due to an attractive force and a repulsive force therebetween
Data Source
AI summary
The present disclosure relates to a motor rotor assembly and a method of aligning a pole center of a permanent magnet thereof. The motor rotor assembly includes a permanent magnet including a plurality of disc type magnet units which have center holes and are segmented in an axial direction, first and second shafts coupled to both end portions of the permanent magnet, a rod which protrudes from a center of the first shaft in the axial direction, is coupled to a center of the second shaft, and passes through the center hole of each of the plurality of disc type magnet units to assemble the permanent magnet, and a sleeve which surrounds an outer circumferential surface of the permanent magnet and fixes the permanent magnet to the first and second shafts, wherein, when the plurality of disc type magnet units are assembled, the plurality of disc type magnet units are formed to have a small amount of magnetic force, pole centers of the disc type magnet units adjacent to each other are aligned due to an attractive force and a repulsive force therebetween, and after the assembly, the plurality of disc type magnet units are fully magnetized to have a preset maximum magnetic force, and polarities of the disc type magnet units, which are adjacent to each other, are formed to be the same.