Rotor Magnet Retention Without Casings for Reduced Magnetic Gap
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Solution Overview
Problem
Existing electric machines face challenges in achieving a high power-to-weight ratio, energy efficiency, reliability, and extended service life, particularly in applications like aircraft where weight reduction is crucial for low energy consumption.
Innovation Solution
A magnet device for electric machines featuring a disc-shaped carrier with form-fit elements and holding parts that securely attach magnets without the need for casings, allowing for smaller magnets and improved magnetic coupling, which reduces weight and enables higher temperature operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If magnets are fastened to a rotor with a casing made of composite materials, then the magnets are securely retained, but the weight of the electric machine increases and the temperature range is limited
Solution Approach 1:
The patent removes the casing component entirely from the rotor structure. Instead of enclosing magnets in a composite material casing, the magnets are directly fastened to the rotor using individual retaining elements and adhesive, eliminating the weight penalty and temperature limitations associated with composite casings.
Solution Approach 2:
The patent replaces composite material casings with a hybrid fastening system combining metal retaining elements (for mechanical strength and temperature resistance) and adhesive (for secure bonding). This combination achieves reliable magnet retention without the weight and temperature constraints of composite casings.
2Power
If a casing is used to fasten magnets to the rotor, then the magnets are retained, but the magnetic gap increases reducing performance
Solution Approach 1:
The patent eliminates the casing that created the magnetic gap. By directly fastening magnets to the rotor surface using retaining elements and adhesive, the magnetic gap is minimized to only what is necessary for mechanical clearance, thereby maximizing magnetic coupling and machine performance.
Solution Approach 2:
Instead of using a casing to retain magnets (which creates distance), the patent inverts the approach by using direct surface fastening methods that pull magnets closer to the stator, minimizing the magnetic gap while maintaining secure retention through mechanical and chemical bonding.
3Temperature
If composite materials are used for the casing, then the magnets are retained, but the temperature range of use is limited
Solution Approach 1:
The patent changes the material parameters of the fastening system by replacing composite material casings with metal retaining elements and high-temperature adhesive. This allows the rotor assembly to withstand higher temperatures while maintaining secure magnet retention, expanding the operational temperature range.
Solution Approach 2:
The patent uses a composite fastening system combining metal retaining elements (for high-temperature mechanical strength) and specialized adhesive (for thermal and chemical bonding). This hybrid approach achieves reliable magnet retention at elevated temperatures without the limitations of organic composite casings.
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 solution results in a more efficient, lightweight, and robust electric machine with improved performance and extended operational temperature ranges, eliminating the need for composite materials and reducing the magnetic gap, thus enhancing energy efficiency and reliability.
Implementation Method 1
The holding part has at least one form-fit element that is in form-fit engagement with the at least one form-fit element of the carrier
Implementation Method 2
For motor operation, these may be acted upon with an alternating electrical field in order to generate a magnetic field that causes the rotor to rotate
Implementation Method 3
generate a magnetic field that causes the rotor to rotate
Implementation Method 4
A support portion and/or adhesive may further be arranged therebetween
Data Source
AI summary
The invention relates to a magnet device (1; 1′) for an electric machine (2) comprising: a support (10); 10′) with a flat support surface (100) and at least one form-fitting element (101); multiple magnets (11) arranged along the support surface (100) about an axis (A); and a holding part (12) which has at least one form-fitting element (120) which engages with the at least one form-fitting element (101) of the support (10; 10′) in a form-fitting manner and has a holding section (121) that is used to hold at least one of the magnets (11) on the support (10; 10′).