Segmented Rotor Assembly for Secure Magnet Retention and Stiffness
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Solution Overview
Problem
Existing rotors for electric machines have reduced stiffness, leading to increased noise-vibration-harshness behavior and potential magnet dislodgment, necessitating additional components like pressure discs and tension rods that increase complexity and cost.
Innovation Solution
A rotor design featuring laminated core segments with magnet pockets accessible only from one end, bonded together to securely capture permanent magnets, eliminating tension rods and end plates, and using force- and form-fit mechanisms to fix magnets, enhancing stiffness and reducing installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tension rods and pressure discs are used to fix laminated core segments, then magnets can be securely fixed in magnet pockets, but rotor stiffness is reduced and noise-vibration-harshness behavior increases
Solution Approach 1:
The invention extracts and eliminates the tension rods and pressure discs from the rotor structure. Instead of using these separate fixation components, the magnet pockets are designed to directly retain the permanent magnets through their geometric configuration and substance-bonded laminated core segments, thereby removing the sources of vibration and stiffness reduction while maintaining magnet security
Solution Approach 2:
The invention merges the functions of magnet retention and structural integrity into the laminated core segments themselves. The substance-bonded connection of laminations creates an integrated structure where the magnet pockets are formed directly in the laminated core, combining the support function and the retention function into a single unified structure without separate fixation components
2Reliability
If tension rods and pressure discs are used to fix laminated core segments, then magnets can be securely fixed in magnet pockets, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and eliminates the tension rods and pressure discs from the rotor structure. Instead of using these separate fixation components, the magnet pockets are designed to directly retain the permanent magnets through their geometric configuration and substance-bonded laminated core segments, thereby removing the sources of vibration and stiffness reduction while maintaining magnet security
Solution Approach 2:
The laminated core segments serve multiple functions simultaneously: they provide the magnetic circuit path, form the magnet pockets, retain the permanent magnets through their geometric design, and provide structural integrity through substance-bonded connections. This multi-functionality eliminates the need for separate fixation components like tension rods and pressure discs
3Ease of manufacture
If magnet pockets are accessible from both end faces, then magnets can be easily inserted, but magnets may fall out unless securely fixed with additional components
Solution Approach 1:
Instead of making magnet pockets accessible from both end faces and then adding fixation components to prevent magnet ejection, the invention inverts the approach by designing magnet pockets accessible from only one end face with a closed end on the other side. This inherent geometric design provides both easy magnet insertion and secure magnet retention without requiring additional fixation components
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
The design increases rotor stiffness, ensures secure magnet retention, reduces noise-vibration issues, and minimizes production costs and space requirements while improving production efficiency.
Implementation Method 1
each has a first end face and a second end face which is spaced apart from the first end face in the longitudinal direction of the laminated core segment, wherein each laminated core segment has at least one magnet pocket extending in the longitudinal direction of the laminated core segment for receiving a permanent magnet
Implementation Method 2
at least two laminated core segments of the rotor are arranged relative to one another such that the respective first end faces of the laminated core segments face one another and are substance-bonded together
Data Source
AI summary
A rotor for an electric machine, having a plurality of annular laminated core segments, wherein each laminated core segment is made of a plurality of laminations are arranged one behind the other and are adhered together, each laminated core segment has a first end face and a second end face. Each laminated core segment is equipped with at least one magnet pocket, which extends in the longitudinal direction of the laminated core segment, for receiving a permanent magnet, the permanent magnet is introduced into the magnet pocket solely from the first end face. At least two laminated core segments of the rotor are arranged relative to each other such that the respective first end faces of the laminated core segments face one another and are adhered together, and the respective second end faces of the distal laminated core segments are oriented outwards in the longitudinal direction of the rotor.