Rotor Flux Concentrator Lamination Structure for Precise Polar Alignment
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Solution Overview
Problem
Existing magnetic flux concentrator structures for brushless DC motors are prone to defects during the bonding and injection molding processes, leading to reduced motor performance due to misalignment and temperature-related issues, which complicates reliable and industrializable positioning and maintenance.
Innovation Solution
A magnetic flux concentrator comprising a stack of sheets with detachable and connected polar elements, where the detachable sheets optimize magnetic properties and the connected sheets ensure precise positioning, using clips and notches for alignment and assembly, and a combination of injection molding and polarization to maintain magnetic resin integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bonding is used to assemble the magnetic flux concentrator, then the rotor structure is formed, but defects appear and magnetic areas shift due to temperature rise
Solution Approach 1:
The magnetic flux concentrator is divided into multiple independent polar elements that are not bonded together. Each polar element is a separate component that can be independently positioned and secured, eliminating the bonding process and its associated defects while maintaining structural integrity through mechanical interlocking.
2Manufacturing precision
If precise positioning is required during injection and polarization, then magnetic properties are optimized, but existing structures do not allow reliable positioning and holding
Solution Approach 1:
The polar elements incorporate self-aligning features including protrusions that fit into recesses and notches that guide positioning during assembly. These features automatically ensure correct alignment and positioning of each polar element without requiring external positioning devices or complex holding mechanisms during injection and polarization processes.
3Ease of manufacture
If glue is used to assemble polar elements, then the rotor is constructed, but the glue melts at high temperature causing magnetic areas to shift
Solution Approach 1:
The bonding agent (glue) is completely removed from the assembly process. Instead of using adhesive to join polar elements, the design relies on mechanical interlocking through protrusions and recesses that create a thermally stable, bond-free construction capable of withstanding high operating temperatures without deformation or magnetic area shift.
4Manufacturing precision
If polar elements are connected by a ring, then positioning is controlled, but the structure becomes more complex
Solution Approach 1:
The ring structure is integrated directly into the polar elements themselves rather than being a separate component. Each polar element includes portions of the ring structure, merging the positioning function into the polar elements and eliminating the need for a distinct, separate ring component while maintaining precise spacing and alignment.
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 facilitates reliable, easy, and industrializable positioning and maintenance of the magnetic flux concentrator, enhancing motor efficiency by minimizing defects and maintaining optimal magnetic properties during assembly and operation.
Implementation Method 1
The magnetic flux concentrator has the effect of increasing a magnetic flux of a permanent magnet of the rotor and thus maximizing a magnetic induction effect between the rotor and a stator
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
Magnetic flux concentrator for a rotor, the rotor comprising a rotary shaft, the magnetic flux concentrator and magnetic regions. The magnetic flux concentrator comprises a stack of laminations (300, 400), the stack of laminations (300, 400) comprising a plurality of laminations of a first type (300) and a plurality of laminations of a second type (400), each lamination of the first type (300) comprising six polar elements which are detached from one another and each lamination of the second type comprising six polar elements (220) which are connected to one another by a ring located at the center of the lamination of the second type (400) and intended to surround the rotary shaft. The polar elements (220) of each lamination of the second type (400) are spaced regularly around the ring and each polar element (220) of one lamination (300, 400) of the stack of laminations is aligned with a polar element (220) of another lamination of the stack of laminations (300, 400) so as to form six regularly spaced stacks of polar elements (220).