Rotor Rotor Mass Non-Parallel Magnet Housing Rows
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Solution Overview
Problem
There is a need to improve the magnetic performance and torque density of rotary electric machines while reducing manufacturing and assembly costs, particularly in high-speed applications such as electric vehicles and industrial power generation.
Innovation Solution
A rotor design featuring a rotor body with stacked laminations and recesses arranged in non-parallel rows, where the first row comprises a U-shape with a central recess free of a magnet and the second row in a V-shape, optimizing the placement and orientation of permanent magnets to enhance saliency torque and reduce magnetic leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If permanent magnets are arranged in parallel rows in conventional rotors, then the structure is simple and manufacturing is easier, but the torque density and magnetic performance are limited
Solution Approach 1:
The patent applies asymmetry by arranging the first and second rows of recesses at different orientations (first row at angle α1, second row at angle α2 where α1 ≠ α2). This asymmetric configuration creates non-uniform magnetic flux distribution that enhances saliency torque while maintaining manufacturability through standardized recess geometries.
Solution Approach 2:
The patent transitions from conventional parallel row arrangements to a multi-dimensional configuration where rows are oriented at different angles relative to the pole axis. This dimensional change in the arrangement pattern enables enhanced magnetic performance by creating complex flux paths that exploit both radial and tangential components of the magnetic field.
2Power
If more permanent magnets are added to increase torque, then the torque output increases, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent applies local quality by making the central recess of the first row optional for magnet placement. This allows flexible configuration where magnets can be placed only in lateral recesses or in all recesses depending on performance requirements and cost constraints, enabling local optimization of the magnetic circuit without uniform increases throughout the entire rotor.
Solution Approach 2:
The patent segments the magnet arrangement into distinct rows with different orientations and optional central recesses. This segmentation allows independent optimization of each row's contribution to torque production, enabling selective placement of magnets to achieve desired performance at lower cost compared to uniform dense magnetization throughout.
3Speed
If the rotor is designed for high-speed operation, then the operational speed increases, but mechanical strength and stability become critical concerns
Solution Approach 1:
The patent applies composite materials by combining laminated magnetic core structures with permanently magnetized components. The lamination structure provides mechanical strength and stability at high speeds while the permanent magnets provide the necessary magnetic field. This composite approach allows the rotor to withstand high-speed centrifugal forces while maintaining magnetic performance.
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 increases torque density without increasing magnet volume, reduces electromagnetic losses and noise, and improves mechanical strength, making it suitable for high-speed operations.
Implementation Method 1
permanent magnets of various geometric shapes... defining poles of the rotor
Implementation Method 2
permanent magnets arranged in non-parallel rows... enhancing saliency torque
Implementation Method 3
rotor body comprising laminations stacked one on top of the other
Data Source
AI summary
A rotor (30) for a rotary electric machine, comprising a rotor mass (33) comprising laminations stacked one on top of the other, the rotor mass (33) comprising a plurality of housings (10), at least some of the housings, or even all of the housings, receiving one or more permanent magnets (1) defining poles of the rotor, the housings of a pole being arranged in at least a first row (11) and a second row (12) of housings which are not parallel to one another, the first row (11) of housings comprising at least three housings arranged in a U shape, with at least one central housing and two lateral housings, the central housing of the first row being able to do without a permanent magnet, the second row (12) of housings comprising housings arranged in a V shape, in particular two housings arranged in a V shape.