Unitary Rotor Structure With Ring Magnet for Abrupt Stop Loads
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Solution Overview
Problem
Electric motors used in high-power applications, such as electric vehicles and power tools, face challenges in withstanding harsh operating conditions like abrupt stops without dislodging parts or creating projectiles, particularly in axial flux motors.
Innovation Solution
The design incorporates a stator and a rotor with a unitary body formed by an integrally forged axial shaft and disc, featuring a ring magnet affixed to the disc, which enhances structural integrity and maintains consistent magnetic field alignment, preventing magnet dislodgment during harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rotor with separate shaft and disc components is used, then assembly flexibility is improved, but structural integrity deteriorates under harsh operating conditions
Solution Approach 1:
The patent merges the shaft and disc components into a single unitary rotor body formed from a single piece of material. This eliminates the interface between separate components, preventing relative motion and ensuring structural integrity during abrupt stop events while maintaining assembly flexibility through the overall rotor design
2Strength
If a unitary rotor body is used, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
While the rotor body is unitary, the patent segments the magnetic field generation into discrete coil assemblies that can be independently manufactured and then assembled onto the rotor body. This allows complex magnetic field requirements to be met without compromising the unitary structure's integrity
3Power
If high power density is achieved, then output performance is improved, but risk of part dislodgment increases
Solution Approach 1:
The unitary rotor body merges all structural components into one piece, eliminating interfaces where parts could dislodge during high-power operation. The ring magnet is securely integrated into this unified structure, ensuring it remains firmly positioned even under the extreme forces of high power density operation
Solution Approach 2:
The patent designs the rotor structure to preemptively counteract the forces that could cause part dislodgment. By creating a unitary body with the ring magnet integrated from the start, the design prevents the possibility of magnet displacement before it can occur during harsh operating conditions
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 unitary rotor body withstands multiple abrupt stoppage events without failure, ensuring consistent magnetic field induction and improved conversion efficiency, while providing increased power density and torque without catastrophic failure.
Implementation Method 1
a ring magnet affixed to the disc
Implementation Method 2
ensuring consistent magnetic field induction
Data Source
AI summary
An electric motor includes a stator and a rotor rotatable relative to the stator. The rotor includes an axial shaft, a disc projecting radially from the shaft, and a ring magnet affixed to the disc. The shaft and the disc are integrally formed as a unitary body.