Offset-Overlap Pole Piece Ring for Low-Leakage Flux Modulation
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Solution Overview
Problem
Conventional modulated ferromagnetic core rings face issues with magnetic flux leakage and structural strength, where adding unilateral ribs enhances structural strength but compromises electromagnetic field performance, and bilateral ribs result in significant magnetic flux leakage.
Innovation Solution
The offset overlap type of modulated ferromagnetic pole piece ring features alternately arranged inner and outer ribs between main ribs, enhancing structural strength and reducing magnetic flux leakage by overlapping ring pieces at specific angles and using a manufacturing method involving sequential stacking and bonding with a colloid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bilateral ribs are added to the modulated ferromagnetic core ring to withstand radial force from both sides, then structural strength is improved, but magnetic flux leakage (eddy current loss) increases significantly
Solution Approach 1:
The rib structure is segmented into three types: main ribs for structural support, inner ribs positioned inside the magnetic flux path, and outer ribs positioned outside the magnetic flux path. This segmentation allows each rib type to serve its specific function without interfering with magnetic flux, resolving the contradiction between structural strength and magnetic flux leakage by distributing structural support functions across different spatial zones.
Solution Approach 2:
The invention transitions from a conventional planar rib structure to a three-dimensional arrangement with ribs at different radial positions (inner, main, outer). By adding the radial dimension to rib placement, the design achieves bilateral radial force resistance while maintaining electromagnetic field performance, as the inner and outer ribs work together to counteract forces from both sides without creating flux leakage paths.
2Strength
If unilateral ribs are added to enhance structural strength, then structural strength is improved, but electromagnetic field performance deteriorates
Solution Approach 1:
Different rib types are assigned to different local regions: main ribs provide structural support, inner ribs are positioned in regions that minimize flux interference, and outer ribs are positioned in non-critical regions. This local differentiation allows the structure to achieve strength enhancement while preserving electromagnetic field performance in critical areas.
3Reliability
If the modulated ferromagnetic core ring is designed to withstand bilateral radial force, then structural reliability is improved, but magnetic flux leakage increases
Solution Approach 1:
The rib system is segmented into functional zones where inner ribs, main ribs, and outer ribs each handle specific aspects of force resistance. The inner and outer ribs work in conjunction to provide bilateral force resistance, while their strategic positioning ensures they do not create continuous flux leakage paths, thus maintaining reliability without generating harmful magnetic flux leakage.
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 effectively addresses magnetic flux leakage and structural strength issues, achieving comparable structural strength to bilateral rib configurations while maintaining electromagnetic field performance, enabling low-speed, high-torque operation and overload protection in built-in gear motors.
Implementation Method 1
bodies of non-magnetic conductive material are used as connectors between the bodies of magnetic conductive material, such as high-strength and high stability epoxy resin
Implementation Method 2
The rotor plays the role of 'flux modulation' in this type of motor and reducer. The 'gear ratio' characteristics are achieved through the magnetic flux modulation effect of the rotor, thereby causing the rotor to generate a speed difference
Implementation Method 3
The structure can not only overcome the serious problem of magnetic flux leakage (eddy current loss), but also enhance the structural strength of the modulated ferromagnetic core ring to have the effect of absorbing vibration and stress
Data Source
AI summary
An offset overlap type of a modulated ferromagnetic pole piece ring and a manufacturing method thereof are provided. The modulated ferromagnetic pole piece ring comprises a plurality of ring pieces overlapped with each other. At least one ring piece comprises a plurality of main ribs, a plurality of inner ribs, and a plurality of outer ribs. The main ribs are arranged in a circular manner with intervals in between, and a plurality of first gaps and a plurality of second gaps are formed alternately between the main ribs, wherein the inner ribs are respectively located in the first gaps, and the outer ribs are respectively located in the second gaps.