Rotor Compressive Structural Elements Preload
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Solution Overview
Problem
Existing electric machine rotors with internal cavities as flux barriers face performance limitations due to non-optimal flux barrier positioning and structural weakening, leading to suboptimal performance and speed constraints, especially in high-speed applications.
Innovation Solution
Incorporating compressive structural elements, such as magnets or non-magnetic materials, within the rotor core cavities that apply a preload between wall features to offset loads from thin structural elements, allowing for higher load carrying capability and improved magnetic performance without increasing feature size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thin lamination features are used to support rotor core parts, then structural weight is reduced and magnetic performance is improved, but the rotor core becomes overly stressed and structural integrity is compromised
Solution Approach 1:
The rotor core is divided into multiple laminations with distributed flux barrier cavities, allowing the structure to be segmented into manageable parts that can support each other, reducing the need for heavy continuous structural support
Solution Approach 2:
The invention changes the physical state and positioning parameters of flux barriers from traditional locations to optimized positions within the rotor core, improving magnetic performance while maintaining structural integrity with thinner features
2Productivity
If flux barrier cavities are positioned non-optimally, then manufacturing is simplified, but magnetic performance and speed capabilities are limited
Solution Approach 1:
The invention optimizes the positioning parameters of flux barrier cavities to specific locations within the rotor core that maximize magnetic performance and speed capability while remaining manufacturable
Solution Approach 2:
Different regions of the rotor core have flux barriers positioned at different optimal locations, with each local area optimized for its specific magnetic and mechanical requirements
3Strength
If lamination feature size is increased to reduce stress, then structural integrity is improved, but the rotor design becomes less compact and material costs increase
Solution Approach 1:
The invention changes the positioning and dimensional parameters of flux barriers to achieve optimal load distribution, allowing thin lamination features to carry sufficient load without increasing overall rotor volume
Solution Approach 2:
The flux barriers are positioned in specific three-dimensional locations within the rotor core, utilizing spatial distribution to achieve structural strength without increasing the rotor's external dimensions
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 solution enhances rotor performance and speed capabilities while maintaining a compact and lightweight design, reducing material costs and structural stress, and effectively addresses the limitations of traditional rotor designs.
Implementation Method 1
A structural element is disposed in the cavity and is compressible between a pair of features of wall. A preload is established between the first and second wall features and the structural element.
Data Source
AI summary
A rotor for an electric machine includes a rotor core having at least one internal cavity. A pair of features are defined by the rotor core and extend into the cavity. A structural element is compressed between the features so that a preload may be established between the features and the structural element.