Rotor Manufacturing via Multi-Layer Winding for Flexible Design
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Solution Overview
Problem
Existing methods for manufacturing synchronous reluctance motor rotors lack flexibility in geometric design, particularly in modifying flux-guiding and flux-blocking sections, leading to complex and unsatisfactory manufacturing processes.
Innovation Solution
A method involving a multi-layer material with magnetically non-conductive and conductive layers, where the conductive layers are embedded between non-conductive ones, allowing for flexible geometric design and connection through winding, heating, or chemical means, enabling variable rotor properties and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional joint punching or combined stamping and laser cutting processes are used to manufacture rotor laminations, then manufacturing capability is maintained, but geometric design flexibility of the rotor is limited and modification of flux-guiding and flux-blocking sections becomes complex
Solution Approach 1:
The rotor body is divided into multiple discrete laminations that can be independently designed and manufactured. Each lamination can have different geometric configurations for flux-guiding and flux-blocking sections, allowing flexible adaptation to various rotor design requirements without complicating the overall manufacturing process
Solution Approach 2:
The invention enables easy modification of geometric parameters such as the shape, size, and arrangement of flux-guiding and flux-blocking sections by changing the lamination design parameters. This allows rapid adaptation to different rotor performance requirements while using the same manufacturing process
2Reliability
If continuous magnetically conductive layers are used in the rotor lamination, then magnetic flux conduction is improved, but eddy currents occur in the axial direction reducing motor efficiency
Solution Approach 1:
The magnetically conductive layers in the laminations are segmented into discrete sections rather than forming continuous paths in the axial direction. This segmentation interrupts eddy current loops while maintaining magnetic flux conduction through the flux-guiding sections, thereby reducing eddy current losses without compromising magnetic performance
Solution Approach 2:
Different regions of the lamination are designed with different magnetic conductivity characteristics. Flux-guiding sections have high magnetic conductivity to guide magnetic flux, while flux-blocking sections have low magnetic conductivity to block flux and interrupt eddy current paths, creating local quality variations that simultaneously improve flux conduction and reduce eddy currents
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 approach significantly enhances manufacturing flexibility and simplifies the process, allowing for optimal adaptation of rotor properties and reducing eddy currents by interrupting the conductive layers, resulting in improved efficiency and reduced iron losses.
Implementation Method 1
This design is primarily intended to prevent eddy currents, which can occur within the rotor during engine operation and have a negative effect on the engine efficiency
Implementation Method 2
each of which has a specific laminating geometry with flux-guiding and flux-blocking sections
Implementation Method 3
a synchronous reluctance motor
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The method involves wrapping a magnetic non-conductive layer and a magnetic conductive layer (4) on a base body, which is formed as a cylindrical body. Individual layers of a winding are interconnected with each other. A multi-layer material (1) is wrapped with the magnetic non-conductive layer and the magnetic conductive layer on the base body, where a laminate (10) or an insulating rectangular wire is utilized as the multi-layer material. The individual layers are firmly bonded and/or positively connected with each other through a gap pipe. The individual layers of the winding are designed as individual rectangular wire layers. An independent claim is also included for a rotor for a synchronous reluctance machine.