Permanent Magnet Rotor Core Structure for Compact Vibration Stability
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Solution Overview
Problem
Existing rotor cores for permanent magnet rotors in household appliances face challenges in providing a stable, compact, and vibration-resistant design while optimizing space utilization and cooling efficiency.
Innovation Solution
A rotor core design featuring a hollow shaft combined with a carrier portion that supports a ring-shaped permanent magnet both radially and axially, using a support plate and elements to ensure rigidity and a compact structure, with optional features like additive manufacturing and stainless steel materials for durability and cooling fluid passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-piece rotor core formed from one metal sheet is used, then manufacturing simplicity is improved, but structural stability and vibration resistance deteriorate
Solution Approach 1:
The rotor core is divided into multiple separate components: a shaft, a carrier with support plate, and support elements. These segments are permanently combined to form the complete rotor core structure. This segmentation allows each component to be optimized independently while maintaining manufacturing simplicity through modular assembly.
Solution Approach 2:
Multiple separate components (shaft, carrier, support plate, support elements) are permanently combined through joining processes to create a unified rotor core structure. This merging of components achieves structural stability and vibration resistance while maintaining ease of manufacture through modular construction.
2Reliability
If the carrier portion extends far in radial direction to support the permanent magnet, then support stability is improved, but space utilization deteriorates
Solution Approach 1:
Instead of extending the carrier radially to achieve support stability, the design uses axial extension of support elements into the interior space of the permanent magnet. This dimensional shift from radial to axial support provides stable magnet retention while maintaining a compact radial profile for better space utilization.
Solution Approach 2:
The support elements are positioned to extend into the interior space surrounded by the ring-shaped permanent magnet, effectively nesting the support structure within the magnet's own volume. This allows the carrier to provide adequate support stability without increasing the overall radial dimensions, thus improving space utilization.
3Temperature
If the hollow shaft is made larger to improve cooling efficiency, then cooling performance is improved, but device complexity and space utilization deteriorate
Solution Approach 1:
The hollow shaft serves multiple functions: it provides the structural axis for rotor assembly, acts as a bearing mounting surface, and functions as a cooling fluid passage. This multi-functionality allows adequate cooling efficiency without requiring additional separate cooling components, thus avoiding increased device complexity.
Solution Approach 2:
The hollow shaft's cooling passage is optimized with appropriate diameter and positioning to provide sufficient cooling efficiency for the motor's thermal requirements. The local dimensions are carefully selected to achieve effective cooling without unnecessarily increasing the shaft size, thereby maintaining good space utilization and avoiding excessive structural complexity.
Data Source
AI summary
A rotor core includes a hollow shaft and a carrier portion permanently combined with the hollow shaft and configured to carry a ring-shaped permanent magnet coaxially to the hollow shaft. The carrier portion includes a support plate extending in radial direction and at least one axial support region configured to support the ring-shaped permanent magnet in axial direction. The carrier portion further includes at least one support element configured to extend into an interior space surrounded by the ring-shaped permanent magnet. A permanent magnet rotor including the rotor core, an electric motor, an electric pump and a household appliance, are also provided.