Permanent Magnet Rotor Segmentation for Assembly and Cooling
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Solution Overview
Problem
Large permanent magnet generators face challenges in manufacturing and maintenance due to cumbersome assembly processes and complex access for replacing damaged magnets, especially in large-scale applications like wind turbines, where cooling systems further complicate the assembly and lead to non-homogeneous cooling.
Innovation Solution
A permanent magnet rotor design featuring modular permanent magnet modules with inclined magnets and integrated cooling channels, allowing for easier assembly, maintenance, and improved torque and power characteristics, with anchors for secure fixation to the rotor rim and radial holes for bolted attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hundreds of magnets are attached by screwing or gluing to the circumference of the rotor, then the generator can be assembled, but the manufacturing process becomes cumbersome and maintenance becomes very expensive
Solution Approach 1:
The rotor is divided into multiple rotor segments, each containing a subset of permanent magnets. This segmentation allows the rotor to be assembled in manageable sections rather than requiring all hundreds of magnets to be installed simultaneously, significantly simplifying the manufacturing process and enabling modular maintenance.
2Ease of repair
If one or more magnets are damaged and need to be replaced, then the generator can be maintained, but the access to these magnets is complicated especially with large size generators
Solution Approach 1:
By dividing the rotor into segments, damaged magnets can be accessed and replaced by working with individual rotor segments rather than disassembling the entire large rotor. This modular approach makes maintenance feasible even for large-scale generators.
Solution Approach 2:
The permanent magnets are extracted from the rotor structure and mounted on separate rotor segments. This extraction allows magnets to be independently removed and replaced without requiring access to the interior of the complete rotor assembly, greatly facilitating maintenance.
3Temperature
If radial cooling holes are drilled in the rotor, then cooling can be provided, but the manufacture and assembly are further complicated and cooling is not homogeneous
Solution Approach 1:
The cooling function is merged with the rotor segment structure itself. Cooling channels are integrated into the rotor segments, allowing coolant flow through the magnetic material without requiring separate radial holes drilled into the rotor body, thus avoiding manufacturing complications while achieving homogeneous cooling.
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
Facilitates simplified assembly and maintenance, enhances cooling efficiency, and improves power and torque performance by enabling easy insertion and removal of magnet modules and providing effective cooling without complicating the manufacturing process.
Implementation Method 1
permanent magnets with a circumferential magnetic orientation
Implementation Method 2
Each of the permanent magnets has a circumferential magnetic orientation
Implementation Method 3
The permanent magnet modules may comprise a central cooling channel arranged between the first and second rows of magnets
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A permanent magnet rotor comprising a rotor rim and a plurality of permanent magnet modules arranged on the outer or inner circumference of the rotor rim, the permanent magnet modules extending generally along an axial direction and being of substantially constant axial-cross section, and comprising a base adapted to be fixed to the rim of the generator rotor, one or more permanent magnets, and one or more pole pieces, wherein each of the permanent magnets has a circumferential magnetic orientation and is substantially rectangular in axial cross-section and wherein each of the permanent magnets is inclined with respect to the central radial plane of the module.