Solid Magnet Rotor Assembly for Compressor Shaft Connection
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Solution Overview
Problem
The design of electric rotor and its connection to the compressor shaft in turbochargers is complex and not compatible with large-scale industrial manufacturing processes, leading to manufacturing tolerances and balancing issues, which affects the magnetic performance and efficiency of the electric machine.
Innovation Solution
A compression device driven by an electric machine with a solid cylindrical magnet and a non-magnetic hoop, where the cylindrical magnet is fixed on a support part by a hoop, eliminating the need for drilling and simplifying the manufacturing process, and allowing for increased magnetic performance and reduced dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a complex rotor design with bore in the magnet is used to connect to the compressor shaft, then the mechanical connection is achieved, but the manufacturing complexity increases and magnetic performance decreases
Solution Approach 1:
The rotor is divided into separate components: a solid cylindrical magnet and a support piece with a bore. The support piece is fixed to the compressor shaft, and the cylindrical magnet is mounted on the support piece. This segmentation eliminates the need for a complex bored magnet structure while maintaining the mechanical connection functionality.
Solution Approach 2:
The support piece acts as an intermediary component between the compressor shaft and the cylindrical magnet. It provides the mechanical connection to the shaft while allowing the magnet to be mounted externally, thus simplifying the overall rotor structure and manufacturing process.
2Reliability
If a solid cylindrical magnet is used without a bore, then the magnetic performance increases, but the connection to the compressor shaft becomes more difficult
Solution Approach 1:
The rotor assembly is segmented into the solid cylindrical magnet and the support piece. The support piece contains the bore for shaft connection, while the magnet remains solid and intact, preserving its magnetic performance. This segmentation allows each component to be optimized for its specific function.
Solution Approach 2:
Instead of creating a bore through the magnet (radial/dimensional modification of the magnet), the connection structure is moved to another dimension by adding a separate support piece. This dimensional shift allows the magnet to remain solid while achieving the required mechanical connection.
3Strength
If the rotor is directly connected to the compression shaft with complex structures, then the mechanical strength is ensured, but the assembly complexity and manufacturing tolerance requirements increase
Solution Approach 1:
The rotor assembly is segmented into the support piece (which connects to the shaft) and the cylindrical magnet (which is mounted on the support piece). This segmentation simplifies the assembly structure, reducing the number of machining operations and balancing requirements while maintaining mechanical strength through the support piece's design.
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 solution simplifies the manufacturing and assembly process, enhances the magnetic performance of the electric machine, and reduces its dimensions, while maintaining mechanical strength and efficiency, making it compatible with large-scale industrial production.
Implementation Method 1
an electrical machine with a small air gap and windings close to the rotor, which allows for optimal guidance of the magnetic flux
Implementation Method 2
the rotor comprises a cylindrical magnet and a ring
Data Source
Figure 1
AI summary
The present invention relates to a compression device driven by an electric machine, for which the rotor (4) comprises a cylindrical magnet (5) and a hoop (6), preferably non-magnetic. According to the invention, the cylindrical magnet (5) is solid, and the cylindrical magnet (5) is fixed to a support part (7) by means of the hoop (6), the support part (7) being fixed on one end of the compression shaft (3).