Electric Motor Rotor Radial Axial Magnet Fixation
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Solution Overview
Problem
Existing methods for attaching permanent magnetic elements to the base body of electric motor rotors are either costly and difficult, such as gluing, or prone to positional shifts during injection molding, leading to imbalanced and inefficient rotor performance.
Innovation Solution
A joining sleeve with chamber walls is used to precisely position and fix permanent magnetic elements on the rotor base body, preventing radial displacement and ensuring axial stability through a locking element molded during injection, eliminating the need for complex attachment methods like gluing or welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent magnetic elements are completely encapsulated with plastic during injection molding, then they are fixed to the base body, but their position shifts during injection molding due to high pressure
Solution Approach 1:
The base body is segmented into multiple bearing surfaces separated by channels, and the joining sleeve is segmented into multiple chamber walls forming separate chambers. Each permanent magnetic element is isolated in its own chamber, preventing相互 interference and position shifts during injection molding while maintaining precise positioning on each bearing surface.
2Reliability
If permanent magnetic elements are glued to the base body, then they are fixed in position, but the process is very difficult and expensive
Solution Approach 1:
The gluing process is replaced with a mechanical fixation system consisting of the joining sleeve with chamber walls that radially secure permanent magnetic elements, and a locking element injected axially to complete the fixation. This eliminates the need for adhesive materials and complex gluing operations, simplifying manufacturing and reducing costs.
3Manufacturing precision
If permanent magnetic elements are fixed in radial direction, then displacement during injection molding is prevented, but additional fixation in axial direction is needed
Solution Approach 1:
The radial fixation function and axial fixation function are merged into a single integrated solution. The joining sleeve provides radial fixation through its chamber walls, while the locking element injected through channels provides axial fixation. Both functions are achieved through one injection molding operation, avoiding the need for separate fixation mechanisms.
4Reliability
If multiple channels are formed on base body to separate bearing surfaces, then joining sleeve is securely fixed against twisting, but channels must be completely filled with injection molding compound
Solution Approach 1:
The channels in the base body are designed to be partially filled with permanent magnetic elements and chamber walls, leaving some channels incompletely filled. This allows injection molding compound to flow through these channels during the locking element injection process, ensuring complete filling and proper fixation without requiring complex multi-step molding operations.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a rotor for an electric motor, wherein the rotor comprises a main body on which at least one support surface is formed, to which at least one permanent magnet element is attached. In order to provide a rotor for an electric motor in which the at least one permanent magnet element is cost-effectively fastened to the main body in a precisely predetermined position, the main body (10) is partially surrounded by a joining sleeve (9) having chamber walls (15), wherein the chamber walls (15), together with the support surfaces (13), form at least one chamber (17) in which the at least one permanent magnet element (5) is arranged, wherein the joining sleeve (9) fixes the position of the permanent magnet element (5) in the radial direction (19) on the main body (10) and a locking element (8) is molded onto the main body (10), said locking element closing the chamber (17) and thereby fixing the position of the permanent magnet element (5) in the axial direction (7) on the main body (10).