Rotor Core with Concave Portions for Electric Power Steering
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Solution Overview
Problem
Conventional electric motors for electric power steering face inefficiencies due to magnetic flux leakage between flux barriers, leading to ineffective utilization of magnetic flux within the rotor core.
Innovation Solution
A rotor core manufacturing method involving laminated steel plates with base and flake portions, where the plates are laminated in an axial direction with gaps and protrusions to create a structure that enhances magnetic flux flow and reduces leakage, utilizing a resin flux barrier to prevent metal interference and improve magnetic flux utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flux barriers with through-holes are used to block magnetic flux, then magnetic flux flow between rotor and stator is improved, but magnetic flux leakage occurs in the steel plate area between flux barriers
Solution Approach 1:
The rotor core is divided into multiple segments including flux barriers with through-holes and resin-filled regions. The resin portions are segmented and placed specifically in the steel plate areas between flux barriers to block leakage paths without interfering with the magnetic flux flow through the through-holes.
Solution Approach 2:
Resin portions are introduced as intermediary materials in the steel plate regions between flux barriers. These resin portions act as mediators to block magnetic flux leakage paths while allowing the flux barriers with through-holes to continue facilitating smooth magnetic flux flow between rotor and stator.
2Manufacturing precision
If protrusions are added to laminated steel plates to fill gaps between flake portions, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Protrusions are pre-formed on the laminated steel plates before final assembly. These protrusions preliminarily occupy the gap spaces between flake portions, ensuring proper positioning and filling of gaps before the resin material is added, thereby simplifying the overall manufacturing process.
Solution Approach 2:
The protrusions and resin portions are combined to form an integrated gap-filling structure. The protrusions provide structural support and positioning, while the resin material fills the remaining spaces, merging two functions into a unified structural element that simplifies manufacturing.
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 method effectively suppresses magnetic flux loops and enhances magnetic flux utilization, improving the motor's magnetic characteristics and reducing cogging torque.
Implementation Method 1
magnetic flux flows smoothly between the rotor and the stator
Implementation Method 2
a leakage of magnetic flux may occur in an area of a steel plate present between flux barriers adjacent in the circumferential direction
Data Source
AI summary
A method of manufacturing a rotor core, the method including laminating first laminated steel plates in an axial direction. The first laminated steel plates each include a plurality of flake portions arranged in a circumferential direction with gaps between each other and a plurality of protrusions protruding radially outward from an outer side surface of a base portion and each having at least a portion located in the gap between the flake portions. The method further includes fixing the base portions to each other and fixing the flake portions to each other. The method further includes removing the protrusions of the laminated steel plates radially outward.