Plastic Encapsulated Rotor Core with Anchored Armature Blocks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric motor rotors with metal laminated armature cores and radial metal connecting sections face challenges in mechanical strength and magnetic flux efficiency, as well as risk of magnet damage during installation.
Innovation Solution
A rotor design featuring a plastic encapsulated core with individually anchored armature blocks and magnets, forming a solid interlocking connection, which eliminates metal connecting sections and optimizes magnetic flux by allowing alternate assembly of armature blocks and magnets, and uses injection-molded sections to secure the magnets within the rotor core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a laminated armature core with radial metal connecting sections is used, then mechanical strength is provided, but magnetic flux efficiency deteriorates due to negative influence of metal connecting sections
Solution Approach 1:
The invention extracts and removes the harmful radial metal connecting sections from the rotor core structure. By eliminating these metal sections that negatively influence magnetic flux, the patent achieves improved magnetic flux efficiency while maintaining mechanical strength through alternative means (plastic encapsulation and anchoring elements).
Solution Approach 2:
The invention employs composite materials by combining plastic encapsulation with metal armature blocks and magnets. The plastic material replaces the problematic metal connecting sections while providing both mechanical strength and magnetic flux efficiency, creating a hybrid structure that leverages the advantages of different materials.
2Ease of manufacture
If magnets are inserted into receiving sections of a laminated armature core, then the rotor structure is formed, but magnet damage occurs during installation due to scratching
Solution Approach 1:
The invention segments the rotor structure into discrete armature blocks with integrated magnets, rather than inserting magnets into a pre-formed laminated core. This segmentation allows magnets to be positioned and secured without the scratching problem associated with traditional insertion methods into receiving sections.
Solution Approach 2:
The magnets are preliminarily attached to the armature blocks before final assembly into the rotor. This preliminary action ensures proper positioning and protects the magnets from damage during the assembly process, avoiding the scratching that occurs when magnets are forced into pre-formed receiving sections.
3Power
If radial metal connecting sections are used to link the armature core to the shaft, then torque transmission is enabled, but device complexity increases and magnetic flux is negatively influenced
Solution Approach 1:
The invention extracts and eliminates the radial metal connecting sections that complicate the rotor structure. Torque transmission functionality is maintained through the plastic encapsulation and anchoring system, simplifying the overall device while removing components that negatively affect magnetic flux.
Solution Approach 2:
The plastic encapsulation serves multiple functions simultaneously: it provides mechanical strength, enables torque transmission to the shaft, and maintains magnetic flux efficiency by eliminating metal connecting sections. This multi-functionality reduces device complexity while achieving the same power transmission goals.
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 enhances mechanical strength, improves magnetic flux efficiency, and prevents magnet damage during installation, while reducing material usage and weight by eliminating metal connecting sections and allowing for secure anchoring of armature blocks within the plastic rotor core.
Implementation Method 1
the anchoring elements forms a solid interlocking connection to the encapsulated plastic
Implementation Method 2
The plastic of the rotor core therefore ensures the mechanical strength
Implementation Method 3
magnetic flux in a rotor of said kind also improves because the rotor core is instead formed from a plastic, because a connecting section does not negatively influence the magnetic flux
Data Source
AI summary
A rotor for use in an electric motor, and to a method for producing a rotor of this kind. The rotor includes a plurality of armature sections, a plurality of magnets, a rotor core and a plastic encapsulation. The rotor core is formed by the plastic encapsulation from plastic. The armature sections are formed as individual armature blocks which are anchored in the rotor core at least by an anchoring element on their inner side that faces a rotor center axis.