Multipolar Rotor with Loaf-Shaped Permanent Magnets

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Solution Overview

Problem

Existing multi-pole rotors for electric motors face challenges in reducing cogging torque and suppressing certain harmonics, particularly the third harmonic in delta connections, which affect motor efficiency and performance.

Innovation Solution

The design features four adjacent permanent magnets forming a magnetic pole pair with magnetization directions angled between 30° and 60° relative to a reference plane passing through the rotor axis, allowing for optimized curvature and placement to minimize cogging torque and harmonic suppression, with options for varying the radius, shape, and attachment methods to enhance efficiency and manufacturing simplicity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the permanent magnets are arranged with convex curvature to match the rotor circumference, then the rotor structure is simplified and manufacturing is easier, but cogging torque cannot be sufficiently reduced

Engineering Contradiction:
Improve rotor structure simplicityVSAvoidcogging torque
Core Design Contradiction:
Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent applies curvature principle by designing the permanent magnets with a convex curvature that deviates from the rotor's circumferential curvature. Specifically, the magnet's outer surface has a radius of curvature that is larger than the rotor's circumferential radius, creating a deliberate mismatch. This curvature difference modifies the magnetic field distribution in the air gap, effectively reducing cogging torque while maintaining manufacturing feasibility through standardized magnet shapes.

Inventive Principle:
Principle #14Spheroidality (Curvature)

2Device complexity

If the magnetization direction is aligned radially for simplicity, then the magnetic field distribution is uniform, but certain harmonics particularly the third harmonic in delta connection cannot be suppressed

Engineering Contradiction:
Improvemagnetization configurationVSAvoidharmonic content
Core Design Contradiction:
Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent applies asymmetry principle by configuring the magnetization directions of adjacent permanent magnets at different angles relative to the radial direction. Instead of uniform radial magnetization, the magnets are magnetized at specific asymmetric angles (e.g., alternating angles such as 15° and -15° from radial). This asymmetric magnetization pattern creates a magnetic field distribution that suppresses specific harmonics, particularly the third harmonic in delta-connected motors, while maintaining acceptable structural simplicity.

Inventive Principle:
Principle #4Asymmetry

3Power

If the permanent magnets are closely spaced to maximize magnetic pole density, then the motor power density increases, but cogging torque increases due to stronger magnetic interactions

Engineering Contradiction:
Improvemotor power densityVSAvoidcogging torque
Core Design Contradiction:
PowerVSObject-affected harmful factors

Solution Approach 1:

The patent applies parameter changes principle by optimizing multiple parameters simultaneously: the convex curvature radius of the permanent magnets, the magnetization angles, the magnet arc spacing, and the magnet height. By carefully selecting these parameters, the patent achieves a balance where magnets can be closely spaced to maintain high power density while the specific curvature and angle configurations reduce magnetic interactions that cause cogging torque. The key parameter is the magnet's outer radius of curvature being deliberately larger than the rotor circumferential radius.

Inventive Principle:
Principle #35Parameter changes

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 configuration effectively reduces cogging torque and suppresses harmonics, improving motor efficiency and reducing production complexity and costs, while allowing for flexible optimization of design parameters to suit specific motor configurations.

Implementation Method 1

the magnetization direction of each individual permanent magnet not running in a radial direction but towards one Reference plane, which runs through the axis of the rotor and through the center of the respective permanent magnet, encloses an angle α between 30° and 60°

Methodology Applied
Scientific EffectMagnetization: Magnetism

Data Source

PatentEP3451502B1Multipolar rotor with loaf-shaped or pie segment permanent magnets
Publication Date: 2022.10.05 MAXON MOTOR AG
  • EP3451502B1 patent drawingFigure 1
  • EP3451502B1 patent drawingFigure 2
  • EP3451502B1 patent drawingFigure 3

AI summary

The present invention relates to a multipole rotor for an electric motor, wherein the rotor comprises a rotor core and several individual permanent magnets distributed around the circumference of the rotor and exhibiting a convex curvature on the side facing the air gap between a stator of the electric motor and the rotor, in a cross-section of the rotor perpendicular to an axis of the rotor. According to the invention, four permanent magnets arranged adjacent to one another in the circumferential direction of the rotor together form a magnetic pole pair, wherein the magnetization direction of each individual permanent magnet forms an angle between 30° and 60° with respect to a reference plane passing through the axis of the rotor and through the center of the respective permanent magnet.