Synchronous Motor Rotor Removal Using Opposing Stator Fields
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Solution Overview
Problem
The existing methods for repairing permanently excited synchronous machines in motor vehicles are hindered by the immense magnetic forces between the rotor and stator, making it impractical to replace or remove the rotor in a repair shop without costly and complex multi-axis robots.
Innovation Solution
A maintenance mode is introduced where the pulse inverter energizes the stator windings to generate a stator magnetic field that opposes the permanent magnetic field of the rotor, reducing the magnetic forces and enabling the rotor to be removed or replaced in a repair shop, using a controller and potentially a diagnostic device to activate this mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the rotor is removed or installed in a normal repair shop, then the repairability and maintainability of the synchronous machine is improved, but the immense magnetic forces between the rotor and stator make this impossible without specialized equipment
Solution Approach 1:
The patent changes the magnetic field parameters by energizing the stator windings with specific currents that generate a magnetic field opposing the permanent magnet field. This parameter change reduces the net magnetic force between rotor and stator, enabling safe rotor removal and installation in repair shops without specialized equipment
Solution Approach 2:
The stator magnetic field acts as an intermediary force that mediates between the permanent magnet field and the mechanical removal process. By introducing this intermediate magnetic field through the stator windings, the patent creates a controlled environment where the rotor can be safely detached despite the strong permanent magnet forces
2Reliability
If the entire synchronous machine is replaced instead of just the rotor, then the reliability of the system is maintained, but the cost and resource consumption increase significantly
Solution Approach 1:
The patent segments the synchronous machine into separable components (stator and rotor) that can be independently serviced. By enabling rotor-only replacement through the magnetic force reduction method, the system allows selective replacement of only the faulty component rather than the entire machine, reducing material consumption while maintaining reliability
Solution Approach 2:
The patent enables recovery and reuse of the stator assembly by allowing separate rotor replacement. The functional stator can be retained and paired with a new or refurbished rotor, thereby recovering valuable materials and components that would otherwise be discarded in a complete machine replacement
3Manufacturing precision
If multi-axis robots are used to install the rotor, then the manufacturing precision and safety are improved, but the device complexity and cost increase making it unsuitable for repair shops
Solution Approach 1:
The patent enables the synchronous machine to perform self-service during rotor installation by using its own stator windings to generate the magnetic field reduction effect. This self-generated assistance eliminates the need for external complex positioning equipment, allowing repair shop technicians to perform precise rotor installation using simple tools
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 simplifies and cost-effectively allows for the repair of rotors in motor vehicles, reducing the need for replacing entire synchronous machines and enabling direct maintenance in repair shops, thereby saving time and resources.
Implementation Method 1
the stator windings are energized by the pulse inverter in a maintenance mode for generating a stator field acting against the permanent magnetic field generated by the permanent magnet of the rotor
Implementation Method 2
the forces occurring between the stator and the rotor are reduced and/or at least partly canceled
Data Source
AI summary
A method for adding or removing a rotor having at least one permanent magnet of a permanently excited synchronous machine in a motor vehicle, which also includes a stator having one or more stator windings, wherein the permanently excited synchronous machine and a pulse inverter connected to the one or more stator windings form a motor arrangement, wherein upon adding or removing the rotor the stator windings are energized for generating a stator field acting against the permanent magnetic field generated by the permanent magnet of the rotor by the pulse inverter in a maintenance mode, such that the forces occurring between the stator and the rotor are reduced and/or at least partly canceled.