Segmented Rotor Assembly with Non-Magnetic Sleeve for Flux Concentration
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Solution Overview
Problem
The production of single-segment rotors for electrical machines with flux concentration is hindered by high manufacturing costs and complex assembly due to the need for numerous individual laminated core segments and magnetic components, which complicates the manufacture and assembly of non-magnetic material paths and torque transmission.
Innovation Solution
A method involving a shaft with spaced-apart laminated core segments and permanent magnets, where a cross-shaped sleeve device is materially connected to the segments, facilitating automated assembly and improved torque transmission through axially extending positioning elements, and allowing for magnetic isolation using non-magnetic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual laminated core segments are used to achieve low scattering and flux concentration, then magnetic performance is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The rotor is divided into individual laminated core segments distributed around the shaft circumference, with each segment separated by non-magnetic material. This segmentation enables flux concentration and low scattering while maintaining manageable assembly through the standardized sleeve device connection system.
Solution Approach 2:
A sleeve device made of non-magnetic material is introduced as an intermediary component to connect and position the laminated core segments on the shaft. The sleeve device simplifies assembly by providing a unified mounting structure with positioning elements that guide segment placement, reducing overall assembly complexity despite using multiple segments.
2Ease of manufacture
If complete rotor laminations are used to improve mechanical stability and ease of production, then manufacturing is simplified, but magnetic flux is short-circuited
Solution Approach 1:
Instead of using complete rotor laminations, the rotor employs segmented laminated core segments separated by non-magnetic material. This segmentation prevents magnetic flux short-circuiting while maintaining production ease through standardized segment manufacturing and assembly using the sleeve device.
Solution Approach 2:
Non-magnetic material is strategically placed locally between adjacent laminated core segments to prevent flux short-circuiting in specific regions. This localized intervention maintains magnetic flux performance while preserving the simplicity of using standardized laminated segments for manufacturing.
3Reliability
If non-magnetic material is used to isolate segments magnetically, then flux concentration is improved, but torque transmission and positioning become more difficult
Solution Approach 1:
The sleeve device made of non-magnetic material serves as a mediator that provides both magnetic isolation between segments and mechanical support for torque transmission. The sleeve device's structure includes positioning elements and connection features that enable effective torque transfer despite the non-magnetic material's inherent limitations.
Solution Approach 2:
The rotor employs a composite structure combining laminated core segments with non-magnetic sleeve device material. This composite approach allows the non-magnetic material to provide magnetic isolation for flux concentration while the overall assembly maintains torque transmission capability through the integrated sleeve device and segment connection system.
4Reliability
If multiple individual segments are assembled to achieve flux concentration, then magnetic performance is improved, but manufacturing cost increases
Solution Approach 1:
The rotor uses segmented laminated core segments to achieve flux concentration and low scattering magnetic performance. The segmentation is made cost-effective through the standardized sleeve device that simplifies assembly and enables automated manufacturing processes.
Solution Approach 2:
The sleeve device performs multiple functions simultaneously: it positions laminated core segments, provides magnetic isolation, transmits torque, and enables automated assembly. This multi-functionality reduces the need for additional specialized components, thereby controlling manufacturing costs while achieving improved magnetic performance.
Data Source
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AI summary
The aim is to provide a method for improving the serial production of single-segment rotors. Therefore, a method is proposed in which a shaft (1) is provided and several spaced-apart laminated core segments (4) are arranged around the circumference of the shaft (1). A permanent magnet (9) is positioned between each pair of laminated core segments (4). A sleeve device (2) is attached to the shaft (1). The sleeve device (2) is bonded to the laminated core segments (4) so that the laminated core segments (4) are held on the shaft (1).