Segmented Back Iron for Magnetic Flux Optimization
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Solution Overview
Problem
Electromagnetic machines face challenges in optimizing magnetic flux return due to limitations in the design of the back iron, leading to magnetic flux saturation and increased costs, particularly in large-scale applications where a single continuous back iron is impractical.
Innovation Solution
The use of a backing member with varying thickness and protrusions in electromagnetic machines, formed from ferromagnetic material, to optimize magnetic flux return by alternating thicker and thinner portions along the width, reducing magnetic reluctance and enhancing flux density uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the size of the back iron is increased to mitigate magnetic flux saturation, then magnetic flux saturation is reduced, but the weight and cost of the electromagnetic machine increase
Solution Approach 1:
The back iron is divided into multiple segments along its length, with each segment having a specific thickness designed to handle the local magnetic flux density requirements. This segmentation allows optimization of material usage while preventing saturation in critical areas.
Solution Approach 2:
Different portions of the back iron have different thicknesses tailored to their specific functional requirements. Areas with higher magnetic flux density have increased thickness to prevent saturation, while areas with lower flux density use minimal thickness to reduce weight and cost.
2Weight of moving object
If the size of the back iron is restricted to minimize weight, then weight is reduced, but magnetic flux saturation occurs in portions of the back iron
Solution Approach 1:
The back iron is segmented into multiple portions along its length, with each segment's thickness optimized for its specific location. This allows the overall weight to be minimized while ensuring that no segment experiences magnetic flux saturation.
Solution Approach 2:
The thickness parameter of the back iron is varied continuously or in discrete steps along its length based on the magnetic flux density distribution. This parameter optimization ensures adequate flux return capacity without excessive material usage.
3Reliability
If a single continuous back iron is used, then magnetic flux return is optimized, but the device becomes impractical for large scale applications due to cost and manufacturing complexity
Solution Approach 1:
The back iron is divided into multiple manageable segments that can be manufactured separately using standard fabrication processes. These segments are then assembled to form the complete back iron structure, making large-scale machines practical and cost-effective.
Solution Approach 2:
Multiple segmented portions of the back iron are combined through assembly to create the complete magnetic flux return path. This modular approach maintains the functional equivalence of a continuous back iron while enabling practical manufacturing and 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 approach allows for improved magnetic flux density distribution and reduced weight and cost in electromagnetic machines, enabling more efficient energy conversion while avoiding magnetic saturation.
Implementation Method 1
The backing member is formed, at least in part, from a ferromagnetic material... optimize magnetic flux return... reducing magnetic reluctance
Implementation Method 2
The backing member is formed, at least in part, from a ferromagnetic material
Implementation Method 3
enhancing flux density uniformity... improved magnetic flux density distribution... avoiding magnetic saturation
Implementation Method 4
avoiding magnetic saturation
Data Source
AI summary
A rotor element configured for movement relative to a stator includes a backing member formed, at least in part, from a ferromagnetic material; a first magnetic pole having a first polarity; and a second magnetic pole having a second polarity, opposite the first polarity. The first magnetic pole and the second magnetic pole are coupled to a first surface of the backing member such that the second magnetic pole is disposed, relative to the first magnetic pole, at a distance defined in a direction of a width of the backing member. A thickness of the backing member is varied along the width of the backing member to form a plurality of alternating first portions and second portions. The first portions include protrusions extending from a second surface of the backing member, opposite the first surface, such that the first portions are thicker than the second portions.