Axially Segmented Electric Machine Magnetic Circuit for Higher Torque
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Solution Overview
Problem
Existing electric machine designs with axially facing plate-like portions have limited structural freedom, making it difficult to increase torque while maintaining the outer shape requirements, and restrict the arrangement of magnetic poles, which limits the flexibility in material selection and assembly accuracy.
Innovation Solution
The electric machine incorporates a structure with armature cores that are magnetically separated and include multiple magnetic pole groups, allowing for a closed magnetic circuit with magnets positioned between magnetic field cores, enabling increased structural freedom, flexibility in material selection, and improved assembly accuracy, while allowing for efficient magnetic flux control and higher output power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two plate-like portions are magnetically coupled at axially extending portions to form a closed magnetic circuit, then the magnetic circuit is formed, but the arrangement of the two plate-like portions is largely limited and freedom in the structure is small
Solution Approach 1:
The invention divides the armature core into multiple independent armature cores (first armature core and second armature core) that are spaced apart in the axis direction. Each armature core has its own magnetic poles, and the magnetic circuits are formed independently between respective magnetic pole groups and the rotor, rather than requiring direct magnetic coupling between two large plate-like portions. This segmentation increases structural freedom while maintaining the closed magnetic circuit function.
2Power
If the two plate-like portions are magnetically coupled, then the magnetic circuit is formed, but it is difficult to increase the torque while satisfying the requirements with respect to the outer shape of the rotary electric machine
Solution Approach 1:
The invention utilizes the axis direction (vertical dimension) to space multiple armature cores apart, creating a three-dimensional magnetic circuit configuration. Instead of being constrained to a single planar arrangement, the magnetic flux paths extend through multiple levels in the axis direction, allowing increased torque output within the same outer shape envelope by effectively utilizing the vertical space between the first and second armature cores.
3Adaptability or versatility
If the two armature cores are magnetically separated, then freedom in the structure increases, but the magnetic circuit arrangement becomes more complex
Solution Approach 1:
The invention segments the magnetic circuit into multiple independent paths, with each armature core forming its own magnetic circuit with the rotor. The first armature core has first and second magnetic pole groups, and the second armature core has third and fourth magnetic pole groups, creating separate magnetic flux paths. This segmentation simplifies the overall magnetic circuit arrangement by eliminating the need for complex magnetic coupling mechanisms between plate-like portions.
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 enhances the structural freedom and material selection flexibility, allowing for increased torque output and improved assembly accuracy, enabling the use of lamination steel instead of powder cores and reducing magnetic saturation, while maintaining the external shape requirements.
Implementation Method 1
A magnetic flux formed by the magnets included in the magnetic path passes through at least one coil to flow in the at least two magnetic pole group pairs
Implementation Method 2
A plurality of coils are respectively provided in the core portions. Each core portion includes two plate-like portions facing each other in the axis direction, and a plurality of magnetic poles protruding radially from each of the two plate-like portions
Implementation Method 3
at least one magnetic field portion that is relatively movable to the armature portion and includes a plurality of magnets and a plurality of magnetic field cores
Implementation Method 4
The two armature cores are magnetically separated. A closed magnetic circuit includes at least two magnetic pole group pairs. A magnetic flux formed by the magnets included in the magnetic path passes through at least one coil to flow in the at least two magnetic pole group pairs
Data Source
AI summary
An electric machine that increases structural freedom to increase output of the electric machine while satisfying requirements of an outer shape. An armature portion includes armature cores (H1, H2) and a plurality of coils (CL) attached to the armature core (H1). A magnetic field portion (Fs) is relatively rotatable to the armature portion and includes a plurality of magnets (Mg) and a plurality of magnetic field cores (22N, 22S). In the magnetic field portion (Fs), the magnets (Mg) are disposed between two magnetic field cores (22N, 22S) adjacent in a rotation direction. Each of the armature cores (H1, H2) includes magnetic pole groups (G1, G2). The magnetic pole group (G1) included in the armature core (H1) and the magnetic pole group (G2) included in the armature core (H2) constitute a magnetic pole group pair (P) that forms a magnetic path through the magnetic field portion (Fs).