Hybrid Rotor Lamination Cavities Using Sintered and Bonded Magnets
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Solution Overview
Problem
Hybrid vehicles face challenges in achieving high torque density and efficiency while minimizing complexity, cost, and emissions, as they typically incorporate both internal combustion engines and electric motors, leading to increased weight and complexity.
Innovation Solution
A hybrid rotor assembly for electric motors is designed, featuring a rotor shaft with a lamination stack containing sintered permanent magnets and bonded magnets, where the lamination cavities are filled with bonded magnets to enhance torque and efficiency, utilizing materials like neodymium-iron-boron for sintered magnets and samarium or neodymium with polymers like nylon for bonded magnets, configured in a V-shape for optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If hybrid vehicles incorporate both internal combustion engines and electric motors, then improved gas mileage and lower emissions are achieved, but drivetrain complexity and weight increase
Solution Approach 1:
The patent extracts the internal combustion engine from the drivetrain, creating an all-electric vehicle configuration. This eliminates the complexity of managing both ICE and electric motor systems while maintaining emission reduction benefits through electric motor-only operation.
2Force
If sintered permanent magnets are used in the rotor, then high magnetic strength and torque are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent employs a composite magnet system combining sintered permanent magnets (for high magnetic strength in critical regions) with bonded magnets (for easier manufacturing in other regions). This composite approach balances magnetic performance requirements with manufacturing simplicity and cost considerations.
Solution Approach 2:
The rotor design places sintered magnets in specific locations where high magnetic flux density is critical for torque production, while using bonded magnets in regions where lower performance is acceptable but manufacturing is simpler. This local differentiation optimizes the balance between performance and manufacturability.
3Productivity
If lamination cavities are fully utilized with magnets, then torque density increases, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses bonded magnets with a binder material that can be injected or compressed into lamination cavities, providing more flexible manufacturing tolerances compared to traditional sintered magnets. This allows fuller utilization of cavity space for higher torque density while maintaining reasonable manufacturing precision requirements.
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 hybrid rotor design achieves a 6-10% increase in motor torque and 1% gain in motor efficiency, addressing the need for high torque density and efficiency while reducing complexity and emissions.
Implementation Method 1
a plurality of sintered permanent magnets contained within the first portion of the plurality of lamination cavities; and a plurality of bonded magnets contained within the second portion of the plurality of lamination cavities
Implementation Method 2
The present invention provides a rotor design optimized for both efficiency and torque
Data Source
AI summary
A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.