Segmented Rotor Yoke for Motor Manufacturing
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Solution Overview
Problem
Current rotor designs for motors and generators, featuring a complete yoke, are costly and complex to manufacture, leading to high production costs and complicated maintenance, especially for large units, and require specialized machinery for assembly.
Innovation Solution
A segmented yoke rotor design where permanent magnets are arranged on individual segments before assembly, allowing for easier manufacturing, assembly, and maintenance, with the option to arrange magnets before or after segment assembly, and using laminated sheet material to reduce eddy current losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complete ring yoke is used in rotor design, then structural integrity is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The yoke is divided into multiple separate segments instead of being manufactured as a single complete ring. Each segment can be manufactured independently using standard machining equipment, then assembled together to form the complete yoke structure. This segmentation reduces manufacturing complexity while maintaining the structural integrity of the overall yoke through proper joining of segments.
2Strength
If a complete ring yoke is used, then structural integrity is improved, but production cost increases
Solution Approach 1:
The yoke is divided into multiple separate segments instead of being manufactured as a single complete ring. Each segment can be manufactured independently using standard machining equipment, then assembled together to form the complete yoke structure. This segmentation reduces manufacturing complexity while maintaining the structural integrity of the overall yoke through proper joining of segments.
3Strength
If a complete ring yoke is used, then structural integrity is improved, but ease of maintenance deteriorates
Solution Approach 1:
The yoke is divided into multiple separate segments instead of being manufactured as a single complete ring. Each segment can be manufactured independently using standard machining equipment, then assembled together to form the complete yoke structure. This segmentation reduces manufacturing complexity while maintaining the structural integrity of the overall yoke through proper joining of segments.
4Loss of energy
If laminated sheet material is used for yoke segments, then eddy current losses are reduced, but manufacturing complexity increases
Solution Approach 1:
The yoke segments are constructed using laminated sheet material, which consists of multiple thin layers of electrical insulation material bonded together. This composite structure reduces eddy current losses by breaking up the conductive paths within the yoke material. The laminated construction is applied to the segmented yoke design, combining the benefits of reduced energy losses with the manufacturing advantages of segmentation.
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 simplifies manufacturing and assembly, reduces production costs, and facilitates easier maintenance by allowing for the exchange of magnets, while minimizing eddy current losses through the use of laminated sheet material.
Implementation Method 1
using laminated sheet material to reduce eddy current losses
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
Rotor for motor or generator, which rotor (11) includes a rotor ring (12), which rotor includes a yoke formed by yoke segments (13) which by arrangement to the rotor ring (12) forms a complete yoke. The yoke segments (13) are provided with one or more magnet blanks (19), which magnet blanks (19) are formed by one or more permanent magnets (18).