Rotor Assembly With Selective Tabs For Multi-Length Magnets
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Solution Overview
Problem
Existing internal permanent magnet electric machines face challenges in efficiently producing rotor assemblies that can accommodate multiple magnet lengths without the need for adhesives, as they require precise alignment and retention mechanisms to secure magnets in place.
Innovation Solution
The solution involves creating rotor assemblies with selectively formed tabs and recesses in lamination sheets, where tabs extend into apertures and are bent to secure magnets, and grooves are used to allow for magnet insertion without binding, enabling the production of assemblies for various magnet lengths using a common stamping tool with different finishing schedules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs and recesses are formed in lamination sheets to secure magnets, then magnet retention is improved, but manufacturing complexity increases
Solution Approach 1:
The rotor assembly is divided into multiple lamination sheets, each with selectively formed tabs and recesses. This segmentation allows magnets to be retained through distributed mechanical features across multiple layers rather than requiring a single complex retention mechanism, thereby improving reliability while managing manufacturing complexity through standardized sheet processing
Solution Approach 2:
Tabs are pre-formed on lamination sheets before final assembly, and recesses are pre-created to guide magnet insertion. This preliminary action ensures proper magnet positioning and retention is established during assembly without requiring complex real-time adjustment mechanisms, improving retention reliability while keeping the manufacturing process straightforward
2Adaptability or versatility
If multiple finishing schedules are used to create different magnet lengths, then adaptability is improved, but manufacturing time increases
Solution Approach 1:
The manufacturing process is made dynamic by implementing multiple finishing schedules that can be selectively applied to lamination sheets based on the required magnet length. This allows the same base lamination structure to be adapted for different magnet configurations through conditional processing steps, improving versatility while managing manufacturing time through efficient schedule selection
Solution Approach 2:
Different finishing operations are applied locally to specific lamination sheets depending on their position in the stack and the desired magnet length. This localized quality approach allows certain sheets to have tabs removed or modified while others retain full features, enabling magnet length variation without requiring complete reprocessing of the entire rotor assembly
3Adaptability or versatility
If tabs are removed selectively from lamination sheets, then production flexibility is improved, but manufacturing precision requirements increase
Solution Approach 1:
Tabs are initially formed on all lamination sheets during a standard finishing operation, then selectively removed in a subsequent controlled process. This preliminary formation ensures consistent starting conditions, and the selective removal can be precisely controlled based on the specific magnet length requirements, balancing flexibility with manufacturing precision through a two-stage process
Data Source
AI summary
An improved rotor assembly configured for magnets with differing lengths, and methods and systems for manufacturing the same. The rotor assembly may be created by selectively creating first and second tabs extending into apertures of lamination sheets. The first and second tabs may be selectively removed, depending on the different magnet lengths and the specific lamination sheet, according to one of a first finishing schedule and a second finishing schedule. The lamination sheets are stacked with any remaining first and second tabs, and other features, aligned.