Resin-Filled Rotor Core Structure for Lower Leakage Flux
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Solution Overview
Problem
Rotors with openings communicating with one end of a magnet insertion hole in a circumferential direction face a trade-off between reduced leakage flux and decreased strength.
Innovation Solution
A rotor design featuring a plurality of cores with magnet insertion holes, first openings, and indent parts, where the nonmagnetic resin is provided in the first openings and indent parts, effectively reducing leakage flux while increasing the rotor's strength by firmly fixing the cores in the axial direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a first opening communicating with one end of a magnet insertion hole in a circumferential direction is provided, then leakage flux is reduced, but rotor strength decreases
Solution Approach 1:
A nonmagnetic resin is introduced as an intermediary material to fill the first opening and indent part. This resin blocks the magnetic flux path that would otherwise create leakage, while simultaneously acting as a bonding agent to strengthen the rotor structure by firmly fixing the core in the axial direction.
Solution Approach 2:
The rotor employs a composite structure combining magnetic core materials with nonmagnetic resin materials. The nonmagnetic resin is strategically placed in the first opening and indent part to create a composite structure that reduces leakage flux while enhancing overall rotor strength through the synergistic combination of materials.
2Loss of energy
If the nonmagnetic resin is provided in the first opening and indent part, then leakage flux is reduced, but device complexity increases
Solution Approach 1:
The nonmagnetic resin serves multiple functions simultaneously: it blocks leakage flux paths, acts as a bonding agent to fix the core, and provides structural support. By merging these multiple functions into a single material placement, the design reduces the need for separate components, thereby simplifying the overall rotor structure despite the addition of the resin.
Solution Approach 2:
The nonmagnetic resin in the first opening and indent part performs multiple roles: magnetic flux blocking, mechanical bonding, and structural reinforcement. This multi-functional approach eliminates the need for separate components for each function, reducing device complexity while achieving the desired performance improvements.
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 design reduces leakage flux and enhances the rotor's strength, allowing for more efficient magnetic flux utilization and improved motor performance.
Implementation Method 1
Magnetic resistance in an opening is generally larger than magnetic resistance in a rotor core
Data Source
AI summary
A rotor includes a plurality of cores stacked in an axial direction, a permanent magnet, and a nonmagnetic resin. The plurality of cores include a magnet insertion hole, a first opening communicating with one end of the magnet insertion hole in a circumferential direction, and an indent part communicating with the first opening and indented in the circumferential direction. The permanent magnet is disposed in the magnet insertion hole. The nonmagnetic resin is provided in the first opening and the indent part.