Axial Flux Rotor Magnet Placement Using Elastic Rim Constraint
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Solution Overview
Problem
Previous axial flux motor/generator designs using ring magnets are complex, expensive to manufacture, and limited in size, while segmented magnets offer more consistent magnetic poles and larger diameter options but pose challenges in placement and centripetal force management.
Innovation Solution
A method and apparatus using a jig with spacers and an elastic member to facilitate the placement of magnet segments onto a back iron, allowing for angular and radial constraint without the need for complex back iron designs, enabling easy automation and consistent magnet placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If segmented magnets are used instead of ring magnets, then manufacturing complexity and cost are reduced, but placement difficulty increases due to centripetal force management challenges
Solution Approach 1:
A jig with elastic members acts as an intermediary device between the magnet segments and the back iron. The jig includes elastic members that press against the magnet segments to counteract centripetal forces during rotation, enabling easy placement while maintaining operational stability. This mediator resolves the contradiction by providing temporary support during assembly that is removed in final operation.
Solution Approach 2:
The jig is used to pre-position and secure magnet segments onto the back iron before the rotor begins rotating. By performing the placement action while the system is stationary, the difficult centripetal force management problem is avoided entirely, as the magnets are already in place when rotation begins.
2Manufacturing precision
If segmented magnets are used, then larger diameter options become available with more consistent magnetic poles, but placement precision requirements increase
Solution Approach 1:
The jig's elastic members automatically adjust to apply appropriate pressure on each magnet segment, ensuring consistent positioning without requiring complex external control systems. The elastic deformation naturally compensates for minor variations in magnet segment dimensions, maintaining precision while keeping the apparatus relatively simple.
3Ease of manufacture
If a simple back iron design is used with segmented magnets, then manufacturing cost is reduced, but magnet retention under centrifugal force becomes problematic
Solution Approach 1:
The jig serves as a mediator that provides the additional retention force needed to counteract centrifugal forces during rotation. By incorporating elastic members that press against the magnet segments, the jig compensates for the simplicity of the back iron design, ensuring reliable magnet retention without requiring a complex back iron structure.
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 allows for the efficient assembly of segmented magnets onto a back iron, reducing manufacturing complexity and centripetal force issues, while maintaining accurate placement and field consistency, enabling larger diameter designs and cost-effective production.
Implementation Method 1
pressing a first end of a magnet segment against an elastic member located at an inner portion of a back iron for a rotor so that force exerted by the elastic member pushes a second end of the magnet segment against a rim located at an outer portion of the back iron
Data Source
AI summary
According to one disclosed method, a magnet segment may be slid linearly along a first surface and onto a second surface of a back iron of a rotor, wherein the first surface is disposed at or above a rim that extends upwardly from the second surface at an outer edge of the back iron to enable the magnet segment to slide over the rim before the magnet segment is slid onto the second surface. According to another disclosed method, a first end of a magnet segment may be pressed against an elastic member located at an inner portion of a back iron for a rotor so that force exerted by the elastic member pushes a second end of the magnet segment against a rim located at an outer portion of the back iron.