Segmented Rotor Magnet Assembly with Fixation Block
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Solution Overview
Problem
The assembly and maintenance of rotating electric machines with strong magnetic forces are hindered by unstable work postures and high attraction forces, leading to reduced workability and increased costs due to the need for precise alignment and handling of magnets during assembly and repair.
Innovation Solution
A rotor structure with magnet units composed of segmented magnet teeth arranged in a circular arc shape, where each magnet tooth has a notch for a fixation block, allowing for stable positioning and easy assembly without the need for separate positioning jigs or welding, enabling press-fitting for secure attachment to the rotor main body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If magnets with stronger magnetic force are used to achieve more compact and efficient rotating electric machine, then the machine efficiency is improved, but the magnets are swiftly drawn to rotor main body by attraction and may crack during assembly
Solution Approach 1:
The rotor is divided into a rotor main body and a separate rotor core, with the rotor core being further segmented into multiple magnet units. This segmentation allows magnets to be assembled on the smaller rotor core away from the rotor main body, reducing magnetic attraction forces during assembly while maintaining the desired compact and efficient design.
Solution Approach 2:
The rotor core acts as an intermediary component between the rotor main body and the magnets. It provides a platform for magnet assembly that is spatially separated from the rotor main body, thereby mediating the magnetic attraction forces and enabling safer assembly of strong magnets.
2Shape
If magnets are assembled on the outer circumference of the disk-shaped rotor, then the rotor structure is formed, but operation postures become unstable due to strong attraction force between adjacent magnets of opposite polarity
Solution Approach 1:
The rotor core is divided into multiple independent magnet units, each carrying one or more magnets. This segmentation allows each magnet unit to be stabilized independently, improving overall operational stability while maintaining the required rotor shape.
3Ease of repair
If the rotor and stator are disassembled for repair and maintenance, then maintenance can be performed, but workability is lowered and work period is prolonged due to strong magnetic attraction force
Solution Approach 1:
The rotor core with magnet units can be disassembled as a separate component from the rotor main body, enabling maintenance work to be performed on the rotor core without necessarily disassembling the entire rotor-stator assembly. This reduces the time and complexity of maintenance operations.
4Ease of manufacture
If discretely provided rotor core with circular arc shape is used to improve assembling workability, then magnet assembly can be carried out on smaller core, but material yield is poor and cutting and polishing are required after casting
Solution Approach 1:
The rotor core is divided into multiple magnet units that can be manufactured separately and then assembled. This segmentation allows for more efficient material utilization compared to manufacturing a complete circular arc rotor core, reducing material waste while maintaining the necessary geometry for magnet assembly.
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 design enhances the productivity and maintainability of rotating electric machines by improving workability during assembly and allowing for independent disassembly and reassembly of magnet units, reducing costs and time required for maintenance.
Implementation Method 1
A fixation block is press-fitted in a pair of the notches, with the plurality of magnet teeth being arranged in the circular arc shape. The fixation block is fastened to the rotor main body, with the fixation block being inserted in the notches.
Data Source
AI summary
A rotor in a rotating electric machine including a rotor main body and at least one magnet unit provided at an outer circumferential part of the rotor main body. The magnet unit has a plurality of magnet teeth as segments in the circumferential direction. The plurality of magnet teeth that form one magnet unit are arranged in a circular arc shape. At least one pair of magnet teeth in one magnet unit is each provided with a notch. With the plurality of magnet teeth being arranged in the circular arc shape, a fixation block is press-fitted in the pair of notches. The fixation block is fastened to the rotor main body while being inserted in the notches.