Electric Motor Rotor Magnet Layout for Scalable Torque Output
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Solution Overview
Problem
Existing electric motor designs face challenges in achieving variable torque output without significant design changes, especially in types like in-wheel motors, leading to increased costs and time due to limited space for axial growth, and components like busbars add unnecessary length complicating packaging and installation.
Innovation Solution
A rotor assembly with specific magnet pocket configurations and overmold holes, allowing for variable torque output through different magnet combinations, and a stator assembly with hairpin winding segments and busbar placement that minimizes motor length and avoids additional height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the motor design is changed to accommodate higher or lower torque requirements, then the torque output is improved, but the design cost and time increase significantly
Solution Approach 1:
The rotor assembly is segmented into multiple magnet pockets (first group with three pockets, second group with two pockets) that can be independently configured. This segmentation allows selective placement of magnets in different pockets to achieve variable torque outputs without redesigning the entire motor structure.
Solution Approach 2:
The motor design incorporates dynamic configurability through different magnet combinations in the magnet pockets. By changing which pockets are activated and how magnets are arranged, the torque output can be dynamically adjusted for different drive modes (FWD, RWD, AWD) while keeping the physical structure unchanged.
2Ease of manufacture
If the motor length is increased to accommodate additional components like busbars, then the components can be properly installed, but the packaging and installation space becomes problematic
Solution Approach 1:
Instead of extending the motor in the axial direction to accommodate busbars and other components, the design utilizes the radial and circumferential dimensions. Magnet pockets are arranged at different radial positions and angular orientations, allowing components to be integrated within the existing axial footprint without increasing motor length.
Solution Approach 2:
The design nests multiple functional elements within the existing motor structure. Magnet pockets are positioned at different depths and radial locations, allowing busbars and other components to be integrated into the available space without requiring additional axial length, effectively nesting components within the existing envelope.
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
Enables a scalable torque output in electric motors by maintaining the existing design, reducing design changes and costs, while optimizing packaging and installation space.
Implementation Method 1
A motor is a well-known electrical machine that converts electrical energy into mechanical energy using magnetic field linkage
Data Source
AI summary
A motor includes: a stator assembly; and a rotor assembly configured to be rotatable relative to the stator assembly. The rotor assembly includes a rotor body that includes: a first group of magnet pockets including three first magnet pockets; and a second group of magnet pockets including two second magnet pockets, the second group of magnet pockets being positioned closer toward an inner surface of the rotor body than the first group of magnet pockets.