Sensor Magnet Fixation in Motor Rotor
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Solution Overview
Problem
The existing motor designs face issues where the magnet can detach from the shaft due to potential misalignment or loose fixation within the housing cylindrical portion, leading to instability and reduced performance.
Innovation Solution
A rotor design featuring a magnet holder with a circumferential wall and support wall that securely accommodates the sensor magnet, filled with a resin filling member to prevent axial movement and detachment, ensuring the magnet is firmly fixed to the shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the magnet is accommodated in a housing cylindrical portion of a holder, then the magnet can be positioned on the shaft, but the magnet may come out of the housing cylindrical portion to be detached from the shaft
Solution Approach 1:
The holder is divided into a housing cylindrical portion and a separate support wall portion. The support wall is positioned at the bottom end of the housing cylindrical portion to prevent the magnet from falling out axially, while the circumferential wall provides radial containment. This segmentation allows each part to perform its specific function effectively.
Solution Approach 2:
The support wall extends in the axial direction from the bottom end of the housing cylindrical portion, adding axial constraint capability to the originally radial-containing structure. This dimensional extension prevents the magnet from detaching axially while maintaining the radial containment function of the circumferential wall.
2Reliability
If the magnet is securely fixed in the holder, then detachment is prevented, but the holder structure becomes more complex
Solution Approach 1:
The support wall is integrated with the housing cylindrical portion to form a unified holder structure. The support wall is positioned at the bottom end of the housing cylindrical portion, combining the radial containment function of the circumferential wall with the axial support function of the support wall, eliminating the need for separate components.
Solution Approach 2:
The housing cylindrical portion serves multiple functions: it provides radial containment through its circumferential wall, supports the magnet axially through the integrated support wall at its bottom end, and maintains positional stability. This multi-functionality reduces the need for additional specialized 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
This design enhances the stability and magnetic flux emission of the sensor magnet, allowing for downsizing of the rotor while maintaining performance and reducing manufacturing costs through simplified chamfering processes.
Implementation Method 1
a filling that fills an inside of the circumferential wall. The sensor magnet is sandwiched between the support wall and the filling in an axial direction
Data Source
AI summary
A rotor includes a shaft extending along a central axis, a sensor magnet positioned on one axial side of the shaft, a magnet holder that includes a circumferential wall which is open on another axial side and accommodates an end portion on the one axial side of the shaft and the sensor magnet therein, and a support wall positioned on the one axial side of the sensor magnet, the magnet holder being fixed to the shaft, and a filling that fills an inside of the circumferential wall. The sensor magnet is sandwiched between the support wall and the filling in an axial direction.