Electric Machine Rotor with Segmented Magnetic Sectors
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Solution Overview
Problem
Conventional rotor production methods for alternators result in excessive material consumption, with the magnetic sheet metal used being twice the amount necessary for magnetic flux conduction, and components like armatures and inductors are often made from the same material, limiting optimization and increasing costs.
Innovation Solution
The rotor design involves cutting the magnetic sheet into sectors that can be made from different materials based on specific needs, with a support made of stamped sheet metal and sectors that can be offset for improved mechanical cohesion, allowing for reduced material usage and integration of additional components like balancing weights or diode bridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional rotor production methods are used with complete tool cutting, then the magnetic circuit is produced, but material consumption is excessive (twice the material necessary for magnetic flux conduction)
Solution Approach 1:
The rotor is divided into separate functional components: an inductor with its own magnetic circuit and an armature with its own magnetic circuit. Each component is cut from separate sheet metal strips rather than from a single complete tool, allowing independent optimization of material usage for each component's specific magnetic flux requirements.
Solution Approach 2:
Different material grades and thicknesses can be selected for the inductor and armature based on their specific magnetic performance requirements. The inductor can use material optimized for high magnetic flux conduction, while the armature can use material optimized for its specific electromagnetic induction requirements, reducing overall material consumption.
2Ease of manufacture
If armature and inductor are made from the same material grade, then production is simplified, but material optimization and cost reduction are limited
Solution Approach 1:
The patent applies different material grades to different components based on their specific requirements. The inductor can be made from sheet metal with one grade optimized for high magnetic permeability, while the armature can be made from sheet metal with another grade optimized for its electromagnetic requirements, allowing cost-effective material selection for each component.
Solution Approach 2:
The patent changes the material parameters (grade, thickness, composition) independently for the inductor and armature sheets. This allows optimization of magnetic properties, mechanical properties, and cost for each component separately, rather than being constrained to a single material specification for both components.
3Length of stationary object
If the support is made of conventional stacked sheets, then the magnetic circuit is formed, but the longitudinal size is excessive
Solution Approach 1:
The support is formed by bending a sheet metal strip into a curved or annular shape that conforms to the rotor's rotational geometry. This curved configuration provides the necessary structural support and magnetic circuit path while minimizing the longitudinal dimension of the support, allowing for a more compact overall rotor design.
Data Source
Figure 2~6
Figure 3~1
Figure 7~10
AI summary
The invention relates to a rotor of a rotary electric machine, in particular for a flux-switching or wound-rotor machine, a mounting for installing the rotor on a shaft and a plurality of magnetic sectors, preferably in the form of a strip, attached to the mounting.