Segmented Rotor Permanent Magnet Layout for Lower Eddy Current Loss
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Solution Overview
Problem
The manufacturing of permanent magnets for axial flux electric machines faces challenges in minimizing losses and costs while maintaining performance and structural integrity.
Innovation Solution
The method involves forming multiple permanent magnet pieces with specific shapes and attaching them to form partitions that reduce eddy current losses, using different materials for end and middle pieces, and cutting through end pieces to create tangential partitions, while maintaining mechanical strength and forming continuous arcs and edges for efficient magnetic flux distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple permanent magnet pieces are attached to form partitions, then eddy current losses are reduced, but manufacturing complexity increases
Solution Approach 1:
The permanent magnet is divided into multiple separate magnet pieces arranged in an array, with partitions between adjacent pieces. This segmentation interrupts eddy current paths, reducing eddy current losses while maintaining the overall magnetic function through the coordinated arrangement of multiple segments.
2Loss of substance
If different materials are used for end and middle pieces, then material costs are reduced, but manufacturing precision requirements increase
Solution Approach 1:
Different material properties are assigned to different locations within the permanent magnet structure. End pieces use one material while middle pieces use another, optimizing performance and cost for each specific position. This local differentiation allows cost-effective material selection while maintaining overall system performance through precise positioning.
3Reliability
If continuous arcs are formed by inner and outer radial surfaces, then magnetic flux distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The inner and outer radial surfaces of the magnet pieces are formed with curved arc profiles rather than flat surfaces. These continuous arcs guide and distribute magnetic flux more effectively across the magnet structure, improving magnetic field uniformity and performance while the modular piece design keeps manufacturing manageable.
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 results in reduced eddy current losses and lower material costs, enhancing the performance and efficiency of the permanent magnets in axial flux electric machines.
Implementation Method 1
attaching at least one of the side surfaces of each of the PM pieces to one of the side surfaces of another one of the PM pieces to form partitions configured to extend in a radial direction of the rotor
Data Source
AI summary
A method of manufacturing a permanent magnet for a rotor of an axial flux electric machine is described herein. The method includes forming multiple permanent magnet (PM) pieces to have the same shape. Each of the PM pieces has an inner radial surface, an outer radial surface, and a pair of side surfaces extending between the inner and outer radial surfaces. The method further includes attaching at least one of the side surfaces of each of the PM pieces to one of the side surfaces of another one of the PM pieces to form partitions configured to extend in a radial direction of the rotor.