Polymeric Rotor Assemblies with Variable Forming Tooling
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Solution Overview
Problem
Current rotor-stator assemblies lack enhanced capabilities and scalability in terms of magnetic field distribution and torque transmission, with existing materials and manufacturing methods limiting the variability and efficiency of rotor assemblies in various applications.
Innovation Solution
A rotor assembly design incorporating a polymeric body with magnetic particles, such as bonded neodymium iron boron or sintered neodymium magnets, and a tooling arrangement with a variable forming cavity to adjust the length of the rotor assembly while maintaining constant inner diameters, allowing for the creation of rotor assemblies with alternating polar magnetic fields and improved torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional rotor-stator assemblies use conventional materials and manufacturing methods, then the structural integrity and basic functionality are maintained, but the magnetic field distribution and torque transmission capabilities are limited
Solution Approach 1:
The rotor assembly uses a composite material consisting of a polymeric body with embedded magnetic particles (such as bonded neodymium iron boron). This composite structure enables enhanced magnetic field distribution and improved torque transmission capabilities while maintaining structural integrity, directly resolving the contradiction between power output and adaptability.
2Adaptability or versatility
If fixed-length rotor assemblies are manufactured using conventional tooling, then manufacturing simplicity is maintained, but scalability and application-specific optimization are limited
Solution Approach 1:
The tooling arrangement incorporates a variable member that can be adjusted to different positions, dynamically changing the forming cavity volume to produce rotor assemblies of various lengths. This dynamic adjustment capability enables scalability and application-specific optimization without requiring multiple fixed tooling sets, resolving the contradiction between adaptability and device complexity.
Solution Approach 2:
The tooling arrangement is designed as a multi-functional system that can manufacture rotor assemblies of different lengths using a single tooling setup. By incorporating adjustable components and variable forming cavities, the tooling serves multiple functions (producing different rotor lengths) that would otherwise require separate dedicated tooling for each length, thus resolving the contradiction between adaptability and device complexity.
3Stability of the object's composition
If segmented bodies with visible boundaries are used, then manufacturing and assembly are simplified, but aesthetic continuity and structural uniformity are compromised
Solution Approach 1:
The rotor assembly integrates the shaft and body into a unified, continuous structure where the body is formed as a single piece that fully encapsulates the shaft. This merging of components eliminates visible boundaries and seams, achieving structural uniformity and aesthetic continuity while maintaining manufacturing feasibility through processes like injection molding.
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 solution enables the production of rotor assemblies with enhanced magnetic field stability and increased torque capacity, accommodating various applications by adjusting the length and magnetic properties, thereby improving the performance and scalability of rotor-stator systems.
Implementation Method 1
the polymeric material can include magnetic particles... defining a magnetically-susceptible rotor body... magnetizing the magnetically-susceptible rotor body to orient magnetic poles
Implementation Method 2
The tooling arrangement can include a coil that is configured to orient magnetic poles of the body of the rotor assembly
Data Source
AI summary
A rotor assembly for use with a stator is disclosed. The rotor assembly includes a shaft that defines at least one outer diameter. The rotor assembly also includes a body that defines at least one interior diameter. The shaft is received within the at least one interior diameter of the body. The body is provided with a magnetic field with alternating polar arrangements as a function of a circumferential position about a circumference of the body.