Rotor Clamping Ring Deformation Control
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Solution Overview
Problem
The existing methods for retaining commutation magnets on a rotor in electric motors or generators lead to distortion of the clamping ring, causing variations in the distance of commutation magnets from the rotor surface, which affects the accuracy of rotor magnetic flux angle measurement and complicates the manufacturing process.
Innovation Solution
A clamping ring with reduced cross-sectional areas adjacent to mounting points and radial slots is used to localize deformation, ensuring a constant distance of commutation magnets from the rotor surface, combined with adhesive retention and optimized mounting points to prevent distortion and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clamping ring is mounted to the rotor using multiple mounting points, then the commutation magnet ring is retained in place, but the clamping ring becomes distorted causing crinkling effects and varying distances from the rotor surface
Solution Approach 1:
The clamping ring is designed with non-uniform cross-sectional area, being thicker at mounting points and thinner at intermediate points. This local variation in geometry allows the ring to deform preferentially at mounting points while maintaining a flat profile at commutation magnet locations, thus retaining the magnet ring while preserving measurement accuracy.
Solution Approach 2:
The clamping ring cross-section is segmented into regions of different thicknesses - thicker regions at mounting points for localized deformation and thinner regions at intermediate points for maintaining flatness. This segmentation enables differential deformation behavior across the ring structure.
2Manufacturing precision
If adhesive is used to minimize distorting effects of the clamping ring, then measurement accuracy is improved, but the manufacturing process is complicated and assembly time increases
Solution Approach 1:
The clamping ring structure is designed to be self-compensating for distortion through its non-uniform cross-section. The geometry itself provides the solution to maintaining flatness, eliminating the need for additional adhesive materials or complex manufacturing processes. The structure serves its own function of preventing distortion.
3Strength
If the clamping ring is made thicker to prevent distortion, then structural strength is improved, but the risk of distortion at mounting points increases
Solution Approach 1:
The clamping ring employs local quality variation with thicker sections at mounting points to provide structural strength where needed, and thinner sections at intermediate points to maintain flexibility and prevent overall distortion. This localized thickness optimization balances strength requirements with flatness maintenance.
Data Source
AI summary
A rotor for an electric motor or generator, the rotor comprising a housing having a first surface on which a first set of magnets is mounted; and an annular clamping ring for retaining a second set of magnets to a second surface of the housing, wherein the position of the second set of magnets on the second surface allows the position of the first set of magnets to be determined, wherein the annular clamping ring includes a mounting point for allowing the annular clamping ring to be mounted to the housing for retaining the second set of magnets to the second surface, wherein the cross sectional area of the annular clamping ring is reduced in a region adjacent to the mounting point and wherein the annular clamping ring is mounted over the second set of magnets.