Rotor Magnet Alignment via Angular Offset and Interlocking Features
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Solution Overview
Problem
The existing configuration of rotors for electric motors requires significant labor to align magnets due to strong magnetic forces in both rotating and axial directions, leading to decreased productivity in rotor assembly.
Innovation Solution
A rotor design featuring a first and second rotor member with core members and magnet groups, where magnets with the same polarity are shifted by a certain angle, and recessed and protruding portions facilitate accurate and easy alignment through magnetic repulsive and attractive forces, reducing the need for extensive labor and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the first magnets and second magnets are arranged adjacent to each other in the axial direction with strong magnetic forces, then the magnetic coupling between rotor members is improved, but the assembly labor and time required to position the magnets increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-positioning the magnets at specific angular offsets during the manufacturing process. The first and second magnets are arranged with predetermined angular displacements before assembly, so that when the rotor members are coupled, the magnets automatically align in the desired configuration. This eliminates the need for labor-intensive post-assembly adjustment and positioning, significantly improving productivity while maintaining strong magnetic coupling.
Solution Approach 2:
The patent replaces complex mechanical positioning systems with magnetic field-based alignment. Instead of using mechanical guides, fixtures, or adjustment mechanisms to position magnets during assembly, the invention uses the magnetic forces themselves to guide and maintain the correct relative positioning of magnets between rotor members. This substitution of mechanical positioning with magnetic field control reduces assembly complexity and labor requirements.
2Manufacturing precision
If the magnets are positioned precisely to achieve optimal magnetic configuration, then the rotor performance is improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent applies self-service by designing the rotor members with self-aligning features. The first and second rotor members include complementary geometric features (such as protrusions and recesses, or keyed interfaces) that automatically guide the magnets into their precise final positions during assembly. The magnets themselves, through their magnetic forces, assist in the alignment process, so that the system self-corrects positioning errors without requiring external intervention or complex adjustment procedures.
3Strength
If multiple bolts and fastening mechanisms are used to secure the rotor members, then the structural strength and stability are improved, but the assembly time and labor requirements increase
Solution Approach 1:
The patent merges the functions of multiple fastening elements into a single integrated coupling mechanism. Instead of using separate bolts, washers, and locking mechanisms to secure the first and second rotor members, the invention combines these functions into one unified coupling structure that achieves both mechanical securing and magnetic alignment simultaneously. This reduction in the number of fastening components directly reduces assembly time and labor while maintaining structural strength.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary force that supplements mechanical fastening. The magnetic attraction between the first and second magnets acts as a intermediary that holds the rotor members together with significant force, reducing the reliance on numerous mechanical bolts. The magnetic field serves as a mediator that distributes and supplements the mechanical fastening loads, allowing for fewer bolts while maintaining overall structural strength.
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 design enhances productivity by allowing for precise and easy positioning of rotor components, reducing the burden on fastening mechanisms and minimizing the number of required bolts, thus simplifying the assembly process and improving the strength of the rotor structure.
Implementation Method 1
the first magnet and the second magnet, which are adjacent to each other and have the same polarity, being shifted from each other by a certain angle in the circumferential direction
Data Source
AI summary
A first magnet group provided to a first core member and a second magnet group provided to a second core member are adjacent to each other in an axial direction of a rotor. The first magnet group includes a plurality of first magnets arrayed in a circumferential direction of the rotor. The second magnet group includes a plurality of second magnets arrayed in the circumferential direction. The first magnet and the second magnet, which are adjacent to each other and have the same polarity, are shifted from each other by a certain angle in the circumferential direction. One of the first core member and the second core member has a first recessed portion, and another of the first core member and the second core member has a first protruding portion to be engaged with the first recessed portion in the circumferential direction.