Sensor Magnet Fixation in Rotary Electric Machine Rotors
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Solution Overview
Problem
Existing methods for fixing a sensor magnet in rotary electric machines, such as those using mechanical tightening or D-shaped mounting with elastic pieces, are inefficient, leading to increased parts count, man-hours, and poor positioning accuracy, which can result in motor noise or breakage due to potential displacement during operation.
Innovation Solution
A rotor design featuring a cylindrical rotor core with insertion holes and an annular sensor magnet with protrusions, where the sensor magnet is firmly integrated with the rotor core using resin, eliminating the need for separate parts and ensuring precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical tightening is used to fix the sensor magnet between two bosses, then the sensor magnet can be prevented from falling off, but the fixing process becomes complex and the risk of sensor magnet breakage increases
Solution Approach 1:
The invention merges the sensor magnet fixation function with the rotor core structure itself. The sensor magnet is embedded directly into the rotor core, eliminating the need for separate bosses and mechanical tightening components. This integration reduces structural complexity while maintaining reliable fixation, as the sensor magnet becomes an integral part of the rotor core assembly.
Solution Approach 2:
The invention extracts the fixation mechanism from the sensor magnet itself and transfers it to the rotor core structure. Instead of modifying the sensor magnet with mounting features, the rotor core is designed with embedded cavities or slots that receive and secure the sensor magnet, thereby simplifying the overall assembly process and reducing the risk of damage during installation.
2Reliability
If D-shaped mounting portions with elastic pieces are used, then the sensor magnet can be fixed to the rotor shaft, but the number of parts increases and mounting time increases
Solution Approach 1:
The invention combines multiple functions into a single integrated structure. The rotor core is designed with built-in embedding structures that simultaneously provide positioning, fixation, and alignment for the sensor magnet. This eliminates the need for separate D-shaped mounting portions and elastic pieces, thereby reducing the number of parts and significantly decreasing mounting time while maintaining reliable fixation.
3Ease of manufacture
If components are placed individually during mounting, then assembly is straightforward, but positioning accuracy decreases leading to displacement and motor noise
Solution Approach 1:
The invention applies preliminary action by pre-forming embedding structures (such as cavities, slots, or recesses) within the rotor core during its manufacturing process. These pre-prepared structures guide the sensor magnet into the correct position during assembly, ensuring high positioning accuracy without requiring complex alignment procedures. The sensor magnet is designed to fit precisely into these predetermined locations, eliminating displacement issues while maintaining ease of assembly.
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 design simplifies the mounting process, reduces the number of parts required, and prevents displacement between the sensor magnet and rotor core, enhancing operational stability and reducing noise by ensuring a secure and accurate integration of the sensor magnet with the rotor core.
Implementation Method 1
the rotor core and the sensor magnet are firmly fixed to each other by resin
Data Source
AI summary
A rotor, a rotary electric machine, and a rotor production method that reduce parts count, allow easy fixing, and prevent displacement. The rotor includes a rotor core having a cylindrical shape and a plurality of insertion holes, and a sensor magnet having an annular shape and placed coaxially with the rotor core, in which the sensor magnet has a plurality of protrusions protruding toward the rotor core, the plurality of protrusions are inserted into the plurality of insertion holes, and the rotor core and the sensor magnet are firmly fixed to each other by resin.