Two-Part Shaft Rotor System for High-Speed Electric Machines
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Solution Overview
Problem
High-speed electrical machine rotors with high-energy rare earth permanent magnets face challenges in achieving a compact, stable, and cost-effective design that maximizes energy density while effectively absorbing centrifugal forces and tolerating temperature fluctuations.
Innovation Solution
A two-part shaft rotor system with a magnetic element receptacle in one shaft part and a connecting rod allowing the two shaft parts to be plugged together, using a material with high mechanical stability and low thermal expansion, and incorporating an elastic compensating element to manage centrifugal forces and tolerance differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece shaft design is used, then structural strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The shaft is divided into two separate shaft parts that can be manufactured independently and then assembled together. This segmentation allows each part to be produced with standard manufacturing processes, reducing overall manufacturing complexity and cost while maintaining the structural integrity needed for high-speed operation.
2Reliability
If magnets are securely fixed to prevent shifting, then reliability is improved, but centrifugal force absorption capacity worsens
Solution Approach 1:
The magnetic elements are arranged in a conical configuration rather than a flat circular pattern. This three-dimensional arrangement allows the magnets to be securely positioned while the conical structure itself helps manage and distribute centrifugal forces more effectively during high-speed rotation.
3Quantity of substance
If maximum active mass of magnets is used, then energy density is improved, but structural rigidity worsens
Solution Approach 1:
The shaft parts are made from composite materials that provide both the necessary structural rigidity to support maximum magnet mass and the mechanical stability required for high-speed operation. The composite construction allows optimization of both strength-to-weight ratio and structural stiffness.
4Ease of operation
If shaft parts are designed for easy assembly, then ease of operation is improved, but connection stability worsens
Solution Approach 1:
One shaft part is designed to be inserted into or nested within the other shaft part, creating a telescopic or nested assembly structure. This nested design enables simple push-together assembly while maintaining stable mechanical connection through the nested interface.
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
The solution enables a compact, stable, and cost-effective rotor system that maximizes energy density, simplifies assembly, and effectively compensates for centrifugal forces and temperature variations, enhancing the operational reliability of high-speed electrical machines.
Implementation Method 1
the shaft part, with its magnetic element receptacle, can suitably absorb the centrifugal forces generated by the at least one magnetic element when rotating a shaft that is connected to the rotor
Implementation Method 2
an at least partially elastic compensating element is provided on the inner peripheral surface of the magnetic element receptacle and/or on the outer peripheral surface of the at least one magnetic element
Implementation Method 3
the connecting rod is made, for example, from a material with the greatest possible mechanical stability and the lowest possible coefficient of thermal expansion
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention relates to a rotor system for an electric machine (1) comprising: at least one magnetic element (5), a two-part shaft (6) with a first shaft part (12) and a second shaft part (13), wherein at least one shaft part (13) has a magnetic element receptacle (16) for receiving the at least one magnetic element (5) and a shaft part receptacle (36) for receiving at least one section of the opposite other shaft part (12).