Electric Machine Rotor Zigzag Pole Skew for Lower Vibration
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Solution Overview
Problem
Conventional rotors for electric machines with linearly skewed pole components can negatively impact vibration and noise behavior, leading to suboptimal performance.
Innovation Solution
A rotor design featuring annularly formed laminated core segments with pole components arranged in a zigzag pattern along the longitudinal direction, where each subassembly of pole components has unique offset positions, reducing the influence of axial, radial, and tangential forces on the stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pole components are arranged with linear skew in the circumferential direction, then the rotor structure is simple and easy to manufacture, but the vibration and noise behavior of the electric machine is negatively influenced
Solution Approach 1:
The patent applies asymmetry by transitioning from a linear skew arrangement to a zigzag-shaped skew arrangement of pole components. The zigzag pattern creates an asymmetric distribution where pole components in different subassemblies are offset in opposite directions, breaking the symmetry that causes harmful vibrations and noise while maintaining manufacturing feasibility through systematic offset positioning.
Solution Approach 2:
The patent implements curvature by replacing the straight linear skew line with a zigzag-shaped skew path. This curved arrangement causes the side faces of pole components to follow a zigzag pattern rather than a straight line, which optimizes the distribution of magnetic forces and reduces the harmful effects on vibration and noise behavior.
2Device complexity
If pole components are arranged with linear skew, then the structural complexity is low, but the vibration and noise generation increases
Solution Approach 1:
The zigzag-shaped skew introduces controlled asymmetry in the pole component arrangement. By offsetting pole components in opposite directions in different subassemblies, the design creates an asymmetric force distribution that cancels out harmful vibrations and noise, achieving better performance without excessive structural complexity.
Solution Approach 2:
The patent segments the pole assembly into multiple subassemblies (first subassembly with at least two pole components, second subassembly with at least one pole component) with different skew characteristics. This segmentation allows each subassembly to be optimized independently, reducing overall vibration and noise while maintaining manageable structural complexity.
3Ease of manufacture
If pole components have uniform offset positions, then the manufacturing process is simplified, but the force distribution in the air gap is suboptimal leading to increased noise and vibration
Solution Approach 1:
The patent applies local quality by assigning different offset positions to different subassemblies of pole components. The first subassembly has offset positions in one direction while the second subassembly has offset positions in the opposite direction. This localized variation in offset positions optimizes force distribution in different regions of the air gap, reducing noise and vibration harshness.
Data Source
AI summary
A rotor for an electric machine, wherein the rotor has a plurality of annularly formed laminated core segments, which are arranged in succession in the longitudinal direction of the rotor, and each laminated core segment has at least one pocket with a pole component arranged therein, wherein the pole components arranged in succession in the longitudinal direction of the rotor form a pole assembly, and the pole assembly has a zigzag-shaped progression in relation to its longitudinal direction.