Rotor Core Balancing Structure for End-Plate-Free Imbalance Correction

Solution Overview

Problem

Existing motor designs face issues with rotor imbalance leading to vibration, noise, and increased weight, size, and cost due to the need for separate end plates for balancing in eco-friendly vehicles.

Innovation Solution

A rotor core balancing structure with preset-shaped balancing structures on the inner circumference of the rotor core, incorporating permanent magnets on the outer circumference, allows for in-situ balancing by identifying and removing mass imbalance points without additional end plates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate end plates are added for balancing operations, then rotor balance correction is achieved, but motor weight, size, and cost increase

Engineering Contradiction:

Improverotor balanceVSAvoidmotor weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The balancing structure is merged with the rotor core itself, integrating the balancing function into the existing rotor structure rather than using separate end plates. This eliminates the need for additional balancing components while maintaining the balancing function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rotor core is designed to serve multiple functions: it provides the structural support for permanent magnets, maintains rotor integrity, and incorporates balancing structures for mass balance correction. This multi-functionality eliminates the need for separate dedicated balancing end plates.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate end plates are added for balancing operations, then rotor balance correction is achieved, but motor size increases

Engineering Contradiction:

Improverotor balanceVSAvoidmotor size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The balancing structure is merged with the rotor core itself, integrating the balancing function into the existing rotor structure rather than using separate end plates. This eliminates the need for additional balancing components while maintaining the balancing function.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate end plates are added for balancing operations, then rotor balance correction is achieved, but manufacturing cost increases

Engineering Contradiction:

Improverotor balanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The balancing structure is merged with the rotor core itself, integrating the balancing function into the existing rotor structure rather than using separate end plates. This eliminates the need for additional balancing components while maintaining the balancing function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rotor core is designed to serve multiple functions: it provides the structural support for permanent magnets, maintains rotor integrity, and incorporates balancing structures for mass balance correction. This multi-functionality eliminates the need for separate dedicated balancing end plates.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Weight of moving object

If balancing structures are integrated into the rotor core, then motor weight and size are reduced, but magnetic interference may occur

Engineering Contradiction:

Improvemotor weightVSAvoidmagnetic interference

Core Design Contradiction:

Weight of moving objectVSObject-affected harmful factors

Solution Approach 1:

The balancing structures are positioned in specific regions of the rotor core where they perform the balancing function while minimizing interference with the magnetic field. The local placement and configuration of balancing structures are optimized to reduce magnetic interference.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The balancing structures act as intermediaries between the rotor core and the permanent magnets, providing mass balance correction while being positioned to minimize disruption to the magnetic flux paths. The design considers the interaction between the balancing structures and the magnetic field.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach facilitates efficient balancing operations, reduces motor weight, size, and cost by integrating balancing structures within the rotor core, minimizing magnetic interference and maintaining performance.

Implementation Method 1

the rotor is rotated by the electromagnetic interaction with the stator

Methodology Applied

Scientific EffectElectromagnetic interaction: Electromagnetic Induction

Data Source

PatentUS11863048B2Rotor core balancing structure and motor including the same

Publication Date: 2024.01.02 HYUNDAI MOTOR CO LTD

AI summary

An embodiment rotor includes a rotor core, a plurality of permanent magnets inserted into an outer circumference portion of the rotor core, and a balancing structure provided on an inner circumference portion of the rotor core, wherein the balancing structure has a preset shape for balancing. An embodiment method for correcting a rotation imbalance of a rotor includes forming a plurality of balancing structures having a preset shape along an inner circumference portion of a rotor core, wherein a plurality of permanent magnets is inserted into an outer circumference portion of the rotor core, identifying a mass imbalance point in the rotor core, and removing a balancing structure of the plurality of balancing structures at a position corresponding to the identified mass imbalance point.