Synchronous Machine Rotor Segmented Core Adhesive Bonding
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Solution Overview
Problem
Existing rotor designs for permanently excited synchronous machines face challenges in achieving leakage resistance and robust manufacturing while maintaining high torque and rotational speed, particularly in withstanding centrifugal forces.
Innovation Solution
A rotor design featuring a laminated core with geometrically different layers, axial and radial adhesive gaps, and a cylindrical sleeve for tangential adhesive gaps, securely fixing permanent magnets within axial pockets to enhance leakage resistance and structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent magnets are arranged within the rotor with conventional fixing methods, then the rotor structure becomes complex with many webs and plates, but this increases manufacturing complexity and reduces ease of manufacture
Solution Approach 1:
The rotor is divided into a laminated core with multiple plates arranged in an axial layering. The plates are segmented into different geometric configurations (first plates with closed outer contour, second plates with plate segments) that create axial pockets for permanent magnets. This segmentation allows for simplified manufacturing while maintaining structural integrity and leakage resistance.
Solution Approach 2:
An adhesive is introduced as an intermediary substance to bond the permanent magnets to the plates within the axial pockets. This adhesive mediator simplifies the fixing process compared to conventional mechanical fixing methods, reducing manufacturing complexity while ensuring reliable attachment and maintaining leakage resistance.
2Ease of manufacture
If the rotor uses a laminated core with geometrically different layers and adhesive gaps, then assembly becomes easier and more automatable, but the structural complexity increases
Solution Approach 1:
The laminated core is segmented into geometrically different layers with specific plate configurations that create self-aligning features. The first plates with closed outer contour and second plates with plate segments form a modular structure that facilitates automated assembly while the resulting axial pockets provide organized positioning for permanent magnets.
Solution Approach 2:
The adhesive gaps are pre-formed during the plate manufacturing process, creating ready-to-use bonding interfaces before assembly. This preliminary preparation of adhesive application surfaces and gap formations enables easier and more automated assembly operations, reducing on-site manufacturing complexity.
3Speed
If the rotor is designed for high rotational speed, then centrifugal force stresses increase, but this can compromise the structural integrity and reliability
Solution Approach 1:
The rotor structure is segmented into multiple thin laminated plates rather than a solid mass. This segmentation reduces the moment of inertia and centrifugal forces acting on any single section, allowing higher rotational speeds while maintaining structural integrity. The distributed plate structure better withstands centrifugal stress distribution.
Solution Approach 2:
Adhesive acts as a mediator that securely bonds the laminated plates and permanent magnets together, creating a unified structure capable of withstanding high rotational speeds. The adhesive gaps provide controlled bonding interfaces that distribute stresses evenly across the rotor assembly, enhancing reliability under centrifugal forces.
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 design achieves a high torque synchronous motor with increased rotational speed and improved rigidity, allowing for easy assembly and automation, while maintaining efficiency and flux concentration, comparable to rare-earth magnets without rotational speed or efficiency losses.
Implementation Method 1
an adhesive provided in radial gaps formed at least in axial sections of the second layer between adjacent plate segments and the permanent magnets
Implementation Method 2
The sleeve is hereby co-rotationally coupled to the shaft and the laminated core with its plates is positioned on this sleeve
Implementation Method 3
the permanent magnets can be arranged in a flux concentration direction within the rotor
Implementation Method 4
the inventive construction also ensures a high rotational speed of the synchronous motor, which also withstands the centrifugal force stresses present in this instance
Data Source
AI summary
A rotor of a permanently excited synchronous machine includes a shaft capable of rotating about an axis and a laminated core having an axial layering arrangement defined by planes which are aligned perpendicular to the axis. The laminated core has at least two layers of different geometry. A first layer has a plate with a closed outer contour at least at an outer periphery, and a second layer has plural plate segments. The first and second layers of the laminated core are arranged in an axial direction to form axial pockets in interspaces between the plate segments of the second layer and recesses formed radially within the outer contour of the first layer for receiving permanent magnets. An adhesive is provided in radial gaps formed at least in axial sections of the second layer between adjacent plate segments and the permanent magnets.