Multi-Pole Component Design Reducing Permanent Magnet Usage
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Solution Overview
Problem
Existing electrical machines are costly due to the high demand for permanent magnets, which are expensive and require significant storage space, and they face challenges in flexible assembly and maintenance due to strong attractive forces between magnetic components.
Innovation Solution
A multi-pole component design for electrical machines that incorporates a first magnetic pole with a permanent magnet and a second magnetic pole made of soft-magnetic materials, such as ferromagnetic metals, which reduces the need for permanent magnets and lowers attractive forces, allowing for cost-effective and flexible assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If all magnetic poles are made with permanent magnets, then the magnetic field strength is improved, but the cost and storage space requirements increase significantly
Solution Approach 1:
The magnetic pole structure is segmented into two distinct types: first magnetic poles equipped with permanent magnets for generating strong magnetic fields, and second magnetic poles made of soft-magnetic materials for magnetic flux conduction without requiring permanent magnets. This segmentation allows the system to achieve necessary magnetic field strength while significantly reducing the total quantity of permanent magnet material required.
Solution Approach 2:
Different regions of the magnetic pole structure are assigned different material properties: permanent magnets are placed only at first magnetic poles where strong magnetic field generation is critical, while soft-magnetic materials are used at second magnetic poles where magnetic flux conduction is the primary function. This local differentiation optimizes material usage by applying permanent magnets only where absolutely necessary.
2Reliability
If all magnetic poles use permanent magnets, then the magnetic performance is improved, but the attractive forces between components increase making assembly and maintenance difficult
Solution Approach 1:
The magnetic pole system is divided into active first magnetic poles with permanent magnets and passive second magnetic poles with soft-magnetic materials. This segmentation creates regions of different magnetic field strength, reducing the overall attractive forces between the secondary part and primary part while maintaining sufficient magnetic performance for reliable operation.
Solution Approach 2:
The magnetic pole structure utilizes parameter changes by switching between permanent magnet material (high coercivity, strong magnetic field) and soft-magnetic material (low coercivity, high permeability) depending on the functional requirements of each pole position. This parameter variation allows optimization of both magnetic performance and mechanical handling characteristics.
3Power
If permanent magnets are used at all magnetic poles, then the feed force is maximized, but the cost of production increases
Solution Approach 1:
The feed force generation is segmented between first magnetic poles with permanent magnets that provide the primary magnetic field, and second magnetic poles with soft-magnetic materials that enhance flux conduction. This segmentation maintains sufficient feed force for effective operation while dramatically reducing the quantity of expensive permanent magnet material required, thereby lowering production costs.
Solution Approach 2:
Soft-magnetic materials used at second magnetic poles are significantly cheaper than permanent magnets. By replacing permanent magnets with these cheaper soft-magnetic materials at positions where full magnetic field strength is not critical, the overall production cost is reduced while maintaining adequate functional performance.
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 design reduces the use of permanent magnet material by approximately 50% and limits feed force loss to 20-25%, enabling more efficient and cost-effective production and maintenance of electrical machines with improved magnetic field concentration and reduced mechanical stress.
Implementation Method 1
a first magnetic pole (13), which has a surface (14) on the top (11)... The first magnetic pole (13) has a permanent magnet (20) with a magnetization in a direction (21)
Implementation Method 2
a winding (61) which interacts magnetically with the multi-pole component (10) via an air gap (4) between the primary part (3) and the secondary part (2) in order to operate the electrical machine (1)
Implementation Method 3
a soft-magnetic device (17), this device having a recess (18) between the first magnetic pole (13) and the second magnetic pole (15)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a multipole component (10, 100) for an electric machine (1, 6), comprising a top (11, 110), a bottom (12, 120), a first magnetic pole (13, 130) having a surface (14, 140) on the top (11, 110), a second magnetic pole (15, 150) having a surface (16, 160) in a tangential direction (22, 24, 220) adjacent to the first magnetic pole (13, 130) on the top (11, 110), and a soft magnetic device (17, 170), wherein the soft magnetic device (17, 170) has a recess (18, 180) between the first magnetic pole (13, 130) and the second magnetic pole (15, 150), with a perpendicular direction (19, 25, 190) from the top (11,110) is directed perpendicular to a tangential direction (22,24,220) to the underside (12,120), wherein the first magnetic pole (13,130) has a permanent magnet (20,200) with a magnetization in one direction (21,210),wherein the second magnetic pole (15,150) does not have a permanent magnet, a secondary part (2,7) for an electric machine (1,6) with the multipole component (10,100), an electric machine (1,6) comprising the multipole component (1,100), as well as a method for manufacturing the multipole component (1,100) or the electric machine (1,6) and a method for servicing the electric machine (1,6).