Segmented Rotor with Flexural Supports and Fastening Ring

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Solution Overview

Problem

The construction of individual-segment rotors for electric motors with flux concentration faces challenges in mass production due to high production costs and issues with scatter resistance, magnetic flux short-circuiting, and torque transmission, particularly in maintaining the positioning and retention of magnets and laminated core segments.

Innovation Solution

The rotor design incorporates radially fastened laminated core segments supported by flexural supports, which are further secured by a fastening ring, allowing for stable retention without affecting magnetic flux and enabling efficient torque transmission, using non-magnetic materials to prevent magnetic scatter and utilizing end plates for additional stabilization and torque transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If individual laminated core segments are used to prevent magnetic flux short-circuiting, then magnetic efficiency is improved, but production cost increases and mass production becomes difficult

Engineering Contradiction:

Improvemagnetic flux short-circuitingVSAvoidproduction cost

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The rotor core is divided into multiple individual laminated core segments that are arranged around the axis of rotation. Each segment is separated by non-magnetic material, preventing magnetic flux short-circuiting while allowing independent manufacturing and assembly of segments, thereby reducing production complexity and cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Non-magnetic material is introduced as an intermediary between adjacent laminated core segments. This intermediary prevents magnetic flux from short-circuiting between segments while allowing the segments to be manufactured separately and assembled efficiently, resolving the contradiction between magnetic efficiency and manufacturing ease.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If individual laminated core segments are not connected together to avoid scatter, then magnetic performance is improved, but mechanical stability and retention become problematic

Engineering Contradiction:

Improvemagnetic scatterVSAvoidmechanical stability

Core Design Contradiction:

Loss of energyVSStability of the object's composition

Solution Approach 1:

Non-magnetic retaining material is used as an intermediary to mechanically connect the individual laminated core segments without creating magnetic flux paths between them. This maintains magnetic performance by preventing scatter while providing the necessary mechanical stability and retention.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The non-magnetic retaining material has properties matched to the laminated core segments, creating a homogeneous assembly structure. This ensures uniform mechanical stability across all segments while maintaining the non-magnetic separation needed to prevent flux scatter.

Inventive Principle:

Principle #33Homogeneity

3Loss of energy

If non-magnetic material is used to separate laminated core segments, then magnetic flux short-circuiting is prevented, but torque transmission capability is reduced

Engineering Contradiction:

Improvemagnetic flux short-circuitingVSAvoidtorque transmission

Core Design Contradiction:

Loss of energyVSForce

Solution Approach 1:

The retaining material is designed with locally optimized properties: non-magnetic in the radial direction to prevent flux short-circuiting, but with sufficient mechanical strength and friction in the axial direction to transmit torque. This local differentiation of material properties resolves the contradiction between magnetic isolation and torque transmission.

Inventive Principle:

Principle #3Local quality

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 achieves stable retention of laminated core segments with low assembly costs, enhances torque transmission, and prevents magnetic scatter, facilitating mass production while maintaining mechanical stability and efficiency.

Implementation Method 1

each laminated core segment in each case is radially fastened to a separate flexural support

Methodology Applied

Scientific EffectFlexural support: Elasticity

Implementation Method 2

all of the flexural supports are radially retained by at least one fastening ring

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Implementation Method 3

the rotor lamination should be constructed so as to be separated by means of 'non-magnetic' material

Methodology Applied

Scientific EffectMagnetic isolation: Magnetism

Data Source

PatentUS9935508B2Individual-segment rotor having individual segments retained by flexural supports and production method

Publication Date: 2018.04.03 SIEMENS AG

AI summary

The aim is to provide an individual-segment rotor, the construction of which requires low production expenditure. For this purpose, an individual-segment rotor having an axis of rotation and a plurality of laminated core segments (5) arranged around the axis of rotation is provided. Each laminated core segment (5) is radially fastened to a separate flexural support (11). All flexural supports (11) are radially retained by at least one fastening ring (14).