Outward Pillar Structures on Rotor and Stator Magnetic Members
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Solution Overview
Problem
The increasing cost of rare-earth metals has made it necessary to design motors that use less rare-earth magnets while maintaining high energy efficiency, as they are crucial for improving the energy product and torque density of brushless permanent magnet motors.
Innovation Solution
The electrical rotor and stator structure incorporates outward pillar structures on the surfaces of magnetic members, which increase magnetic flux density between the rotor and stator, enhancing energy efficiency without relying on excessive rare-earth magnets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rare-earth magnets are used to improve energy product and torque density, then motor performance is improved, but motor cost increases significantly
Solution Approach 1:
The patent applies local quality by adding pillar structures at specific locations on the magnetic member surfaces rather than uniformly throughout. These localized pillars concentrate magnetic flux where needed most, improving torque density and energy product while using minimal additional material, thus avoiding proportional cost increases
Solution Approach 2:
The patent changes the geometric parameters of the magnetic members by adding three-dimensional pillar structures with specific dimensions (height, width, spacing). This modifies the magnetic field distribution and increases the energy product without requiring more rare-earth material, thereby improving performance while controlling cost
2Use of energy by moving object
If more rare-earth magnets are used to increase energy efficiency, then motor performance improves, but material cost rises
Solution Approach 1:
The pillar structures create a controlled porous-like geometry on the magnetic member surfaces, increasing surface area and magnetic flux pathways without adding significant material volume. This allows better flux utilization from the existing rare-earth magnets, improving energy efficiency while maintaining or reducing rare-earth content
Solution Approach 2:
The patent transitions from two-dimensional flat magnetic member surfaces to three-dimensional structures by adding pillars protruding from the surfaces. This dimensional change increases the effective magnetic interaction area and flux density without proportionally increasing the quantity of rare-earth material required
3Use of energy by moving object
If pillar structures are added to increase magnetic flux density, then energy efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The pillar structures are segmented into discrete, uniformly spaced elements rather than continuous complex geometries. This segmentation simplifies manufacturing by allowing standardized production of identical pillar units that can be consistently formed using conventional processes, reducing the actual manufacturing complexity despite the increased structural detail
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
The installation of outward pillar structures on the surfaces of magnetic members in the rotor and stator significantly increases magnetic flux density, leading to improved energy efficiency and reduced reliance on rare-earth magnets, as demonstrated by simulations showing increased magnetic flux and torque.
Implementation Method 1
The plurality of outward pillar structures is installed on the second surfaces and the first surface. The outward pillar structures increase magnetic flux density between the rotor and the stator
Data Source
AI summary
An electrical rotor and stator structure includes at least one stator, at least one rotor and multiple outward pillar structures. The at least one stator includes multiple first magnetic members. Each first magnetic member has a first surface. The at least one rotor is able to be rotated pivotally relative to the at least one stator. The at least one rotor includes multiple second magnetic members. Each second magnetic member has a second surface facing and opposite to the first surface. The multiple outward pillar structures are installed on the second surfaces and the first surfaces.