Rotor Pole Magnetic Orientation During PBM Injection Molding
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Solution Overview
Problem
The manufacturing of permanent magnet synchronous reluctance machine (PMSynRM) rotors with polymer bonded magnets (PBMs) results in inconsistent magnetic field magnitudes due to the magnetic orientation of the permanent magnets, which affects the rotor's performance and yield.
Innovation Solution
A method is introduced to monitor and determine the magnetic orientation of rotor poles in PMSynRM rotors by injecting a magnetic composite material into rotor cavities and applying an external magnetic field to orient the material. This method includes measuring the magnetic field magnitude and comparing it against threshold values to assess the magnetic field orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer bonded magnets are injected into rotor cavities using a molding process, then the rotor can be manufactured with integrated magnets, but the magnetic field magnitude becomes inconsistent due to random magnetic orientation of the permanent magnets
Solution Approach 1:
An external magnetic field is applied during the injection molding process to orient the magnetic particles in the desired direction before the material solidifies. This preliminary action ensures that the magnetic composite material achieves the correct magnetic orientation during injection, resolving the inconsistency issue while maintaining the integrated manufacturing process
Solution Approach 2:
The magnetic properties of the composite material are controlled by changing the magnetic field parameters (strength, direction, timing) during the injection process. By adjusting these magnetic field parameters, the patent achieves consistent magnetic field magnitude and orientation in the final rotor product
2Productivity
If no magnetic field monitoring is performed during injection, then the manufacturing process is simpler and faster, but the manufacturing yield decreases due to inconsistent magnetic field generation
Solution Approach 1:
A magnetic field sensor is positioned to detect the magnetic field generated by the magnetic composite material during or after injection. This feedback mechanism allows real-time monitoring of magnetic field magnitude, enabling the system to verify proper magnetic orientation and identify defective parts, thereby improving manufacturing yield without significantly reducing productivity
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 proposed method improves the consistency and magnitude of the magnetic field generated by the PBM, enhancing the manufacturing yield and performance of PMSynRM rotors by ensuring proper magnetic orientation during the injection process.
Implementation Method 1
applying an external magnetic field to the rotor pole to magnetically orient the magnetic composite material injected into the at least one rotor cavity
Implementation Method 2
measuring a magnitude of a magnetic field of the rotor pole generated by the magnetic composite material
Data Source
AI summary
A method of monitoring a magnetic orientation of a composite magnetic material injected into a rotor pole of a rotor core. The rotor pole is defined by at least one rotor cavity. The method includes injecting a magnetic composite material into the at least one rotor cavity defining the rotor pole and applying an external magnetic field to the rotor pole to magnetically orient the magnetic composite material during injection into the at least one rotor cavity.