Torque-Optimized Rotor with Casting Mold Cohesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotor designs for small electric motors are not suitable for compact structures and suffer from magnetic short circuits, leading to suboptimal torque and stability issues due to protruding inference cores and the need for additional space and complex connections.
Innovation Solution
The inference cores do not protrude over the permanent magnets radially, and are held together by a casting mold with a form closure, eliminating the need for an inner sleeve-shaped structure and screws, ensuring a stable cohesion and optimized torque by using a plastic injection molding that forms a homogeneous cylindrical outer circumference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inference cores are connected by an inner sleeve-shaped structure, then positioning accuracy is improved, but radial space requirement increases and magnetic short circuits occur
Solution Approach 1:
The inference cores are designed as individual separate components rather than being connected by a continuous inner sleeve structure. Each inference core is positioned independently between adjacent permanent magnets, eliminating the need for a connecting sleeve and reducing radial space requirements while preventing magnetic short circuits between cores.
Solution Approach 2:
The inner sleeve-shaped connecting structure is completely removed from the design. Instead of having inference cores connected by a sleeve, each core stands independently and is secured only by the casting mold, extracting the problematic connecting element that caused both space consumption and magnetic short circuits.
2Power
If inference cores protrude radially over permanent magnets, then torque is optimized, but stability decreases due to centrifugal forces
Solution Approach 1:
The inference cores and permanent magnets are integrated into a unified rotor compound held together by the casting mold. The casting mold merges all rotor components (inference cores, permanent magnets, rotor body) into a single stable structure, allowing the inference cores to be positioned optimally for torque while maintaining overall rotor stability through the unifying mold structure.
3Stability of the object's composition
If inference cores are secured by screws, then stability is improved, but device complexity increases
Solution Approach 1:
The casting mold serves as a unifying structure that simultaneously secures all inference cores, permanent magnets, and rotor components together. This single mold structure replaces multiple separate fastening elements (screws, clips, or other securing mechanisms), reducing component count while maintaining stability through the integrated mold design.
4Power
If radial outer sides of inference cores are uncovered, then torque is optimized, but protection against falling out decreases
Solution Approach 1:
The casting mold creates a unified rotor compound where all components are embedded and secured together. The mold structure provides the necessary containment and protection against components falling out, allowing the radial outer sides of inference cores to remain uncovered for optimal torque while the overall mold structure ensures reliability.
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 prevents magnetic short circuits, enhances stability, and optimizes torque in small electric motors by using a casting mold for cohesion, allowing for a more compact and efficient rotor structure.
Implementation Method 1
The primary protection against falling out of the rotor compound due to the centrifugal forces that act onto the rotor during operation of the electric motor
Implementation Method 2
A rotor for an electric motor with a rotor axis, several permanent magnets that are arranged in a spoke-shaped way as well as multiple inference cores
Data Source
AI summary
A rotor for a small electric motor (e.g., electric engine). The rotor having a rotor axis, multiple permanent magnets that are arranged in a spoke-shaped way as well as several inference cores. Each of the permanent magnets has two axial ends, two longitudinal sides, a radial outer side as well as a radial inner side. The inference cores protrude radially over the permanent magnets in relation to the rotor axis. The rotor is enclosed at least partially by a casting mold having multiple struts that extend in an axial direction and that overlap radially with the permanent magnets. The inference cores do not overlap with the permanent magnets on their radial outer sides, wherein both the permanent magnets as well as the inference cores are held together primarily directly by the casting mold in a radial direction.