DESC:TECHNICAL FIELD
[0001] The present invention generally relates to the field of rotating devices. More particularly, it relates to integrated magnet and its holder arrangement in the rotor of a rotating device.

BACKGROUND
[0002] A rotating device or a torque producing rotating device is a machine or mechanism that uses a rotating component to perform a specific function (e.g., to produce a torque). Examples of rotating devices include electric motors, generators, internal combustion engines, steam engines and pumps.

[0003] A magnetic sensing device, also known as a rotor position sensor, is a device used to determine the position of the rotor in a rotating device, such as an electric motor. The sensor typically uses Hall effect sensors, optical sensors or magnetic sensors to detect the position of the magnets on the rotor. This information is used to control the flow of current to the stator windings, ensuring that the motor runs smoothly and efficiently.

[0004] It is very well known in the art that the rotating machines include a shaft, which is a central rotating component of the motor, to which other parts such as the rotor and a balancing plate are attached which is an integral part of the rotating machines. The shaft transmits the torque produced by the motor to the load. The balancing plate attached to the rotor shaft is used to adjust the weight distribution or dynamic unbalance of the rotor. This helps to reduce vibration and improve the smoothness of the motor's operation.

[0005] The rotor shaft has a keyway in which the magnet encompassed core is aligned and the balancing plate is additionally assembled on either side which is constrained through a locknut mechanism. The locknut mechanism constraints all these moving parts through interference fit between the shaft and locknut. An external sleeve is added at end of shaft to accommodate the magnet which is called as magnet holder The magnet holder is then pressed over the shaft in a specific angle for rotor angle sensing.
[0006] Existing methods include magnetic holder for holding magnet in the rotor and other parts are secured through locknut mechanism.

[0007] For example, Japanese Patent Application Number 2021106439 to Nidec Tosok Corp entitled “Electric actuator” discloses an electric actuator comprises: a rotor body which is fixed to a motor shaft; a magnet holder which is fixed to the motor shaft; a magnet which is fixed to the magnet holder and of which the magnetic field is detected by a magnetic sensor; and a locking nut which fixes the magnet holder to the motor shaft and to prevent the magnet holder from rattling with respect to the motor shaft.

[0008] The locking nut mechanism used in the existing methods increase the overall volume or package of the device and is difficult to manufacture which in turn increases the cycle time to complete the assembly process and does not meet the high pressure and temperature operation and contributes to bigger motor length.

[0009] In order to overcome the aforementioned limitations, the present invention proposes a compact, easy to adapt and to avoid balancing of multiple parts, contemplates a rotor arrangement with integrated magnet holder that supports both simply supported and overhang type electric vehicle motors and cantilever rotor designs especially for liquid cooled electric motor devices, but not limited to it.
OBJECTIVE OF THE INVENTION
[0010] The primary objective of the present invention is to provide a compact, easy to balance and adaptable rotor arrangement comprising an integrated magnet holder that supports both the simply supported and overhang type electric vehicle motors as well as cantilever rotor designs.

[0011] Another objective of the present invention is to design an integrated magnet holder with balancing plate that is easy to manufacture with less cycle time due to a smaller number of components.
[0012] Yet another objective of the present invention is to use integrated devices which avoids complex functions and failures that leads to ambiguity of process and addition of process of calibration in motors of electric vehicles (EV) having liquid as a cooling medium.

[0013] Still another objective of the present invention is to allow easier starting of EV motor and easier stopping of the motor during plural rotation requirement in either direction by reducing the total mass of the system which is suspended in liquid medium of variable pressure.

SUMMARY OF THE INVENTION
[0014] The following summary is provided to facilitate a clear understanding of the new features in the disclosed embodiment, and it is not intended to be a full, detailed description. A detailed description of all the aspects of the disclosed invention can be understood by reviewing the full specification, the drawing, and the claims and the abstract, as a whole.

[0015] In order to achieve the aforementioned objectives, the present invention discloses a rotor arrangement with integrated magnet holder and balancing plate for simply supported rotor design and cantilever rotor designs.

[0016] The present invention proposes a permanent magnet structure for rotating devices (e.g., torque producing rotating devices). The structure includes a magnet holding body arranged to have a magnet fixed in central axis vertical to a sensor arranged to be spaced apart from housing in a predetermined distance separated by housing which embodies the rotating device in a liquid medium. The structure includes a shaft includes a torque producing magnets in the rotor arranged to deflect inline to the structure that embodies current carrying coil wounded in single or multiple forms over a ferrous core. The shaft additionally embodies the present invention which integrates both magnet structure and balancing structure to reduce the overall package of the device and reduction of locking nut and extended shaft length which makes the whole device compact and adaptable for both simply supported and overhung or cantilever type rotor assemblies.

[0017] According to present invention, the magnet holder holds magnet in the top of rotor for rotating angle position sensor or rotating encoder purpose, facing the PCB, where PCB have hall effect sensor or optical sensor alike in general designated as on-axis sensor.

[0018] The present invention involves integrating a balancing plate into the magnet holder of a rotor to counteract its rotational motion. To achieve this, it is necessary to select suitable materials that can minimize the inertia of the rotating component and prevent magnetic flux dissipation. Non-ferrous materials like aluminium are a viable option because they have a lower density, which reduces the overall inertia of the system and makes it easier to balance the mass during manufacturing. Other materials may also be suitable, but aluminium is an example of a material that can be used effectively for this purpose.

[0019] In an additional embodiment, the magnet holder with balancing plate also contains internal arrangement to allow flow of cooling fluid or medium during rotation for heat removal where the pressure differences or pressure surge due to cooling liquid flow variations is equalized by this bleed path.

[0020] Thus, the present invention provides compact, easy to balance and adaptable rotor arrangement with an integrated magnet holder and balancing plate that is easy to manufacture, consumes less cycle time, involves less number of components with compact motor package for liquid cooling machines.
BRIEF DESCRIPTION OF DRAWINGS
[0021] The present invention will be better understood fully from the detailed description that is given herein below with reference to the accompanying drawings of the preferred embodiments of the present invention, which, however, should not be deemed to be a limitation to the invention to the specific embodiments, but, are for the purpose of explanation and understanding only.
FIG. 1 illustrates a conventional rotor arrangement with locking nut mechanism according to prior art.
FIG. 2 illustrates the rotor assembly of a rotating device according to prior art.
FIG. 3 illustrates a rotor structure with integrated magnet holder and balancing plate according to an embodiment of the present invention.
FIG. 4 illustrates the integrated holder in the rotor shaft.
FIG. 5 illustrates the area for placing magnet and shows the coolant channel.
FIG. 6 illustrates the coolant flow passage in the shaft in accordance with an embodiment of the present invention; and.
FIG. 7 illustrates an exploded view of magnet, magnet holder with balancing plate and coolant channel in shaft.
[0022] It should be noted that the figures are not drawn to scale. It also should be noted that the figures are only intended to facilitate the description of the preferred embodiment. The figures do not illustrate every aspect of the described embodiment and do not limit the scope of the present invention.

LIST OF REFERENCES
1 - Rear cover
2 - Rear hub
3 - Simply Support Bearing 1
4 – Simply Support Bearing 2
5 - Locking nut
6 - Balancing Plate (Rear)
7 - Balancing Plate (Front)
8 – Coolant channel in shaft
9 - Stator coil
10 - Stator core
11 - Rotor Assembly
12 - Mounting Fastener
13 - Stator housing
14 - Rotor Shaft
15 - Front Hub
16 - Low pressure Oil seal
17 - Load/Impeller
21 – Sensor PCB
22 – Housing
23 – Magnet
24 – Balancing Plate
25 – Rotor shaft
26 – Cooling Channel in shaft
26’ – Cooling channel in magnetic holder
28 – Integrated Magnet Holder
29 – Area for magnet

DETAILED DESCRIPTION
[0023] The following is a description of the present invention depicted in the accompanying drawings. However, it may be understood by a person having ordinary skill in the art that the present subject matter may be practised without these specific details. The subject matter of the disclosure will be more clearly understood from the following description of the embodiments thereof, given by way of example only with reference to the accompanying drawings, which are not drawn to scale.
[0024] The term “simply supported motor” refers to a motor, wherein the rotor is mounted on bearings or other support structures at both ends, allowing it to rotate freely within the stator. The term “overhang motor” refers to motor comprising rotor that extends beyond the bearing support on at least one end. This extension of the rotor beyond the bearing support is called the overhang. The term “cantilever rotor” refers to a rotor configuration where the rotor is supported only on one end due to severe space constraints and to achieve specific performance goals.

[0025] The term “PCB” stands for Printed Circuit Board, where, the PCBs play a crucial role in rotating machines, by providing control, monitoring, power electronics, signal processing, and communication functionalities to ensure efficient and reliable operation.

[0026] The present invention discloses a rotor arrangement featuring an integrated magnet holder and balancing plate in the rotor of a rotating device, specifically suitable for both simply supported and cantilever rotor designs.

[0027] FIG. 1 illustrates a conventional rotor arrangement with locking nut mechanism (5) and FIG. 2 illustrates the rotor assembly (11) of a rotating device, according to prior art. Referring to FIGS.1and 2, the lower end of the rotor shaft (14) is connected or coupled to the driven feature of the load (17), and an internal channel (8) through which the coolant liquid flows into the electrical machine is further depicted. The system is supported by two bearings: Bearing-1 (3) and bearing - 2 (4) as depicted in FIGS.1 and 2. Serving as the front and rear end bearings within the machine, this arrangement suspends and constitutes the dynamic part of the machine. To ensure dynamic uniformity of mass throughout the shaft, balancing plates (6, 7) are affixed on either side of the rotor assembly (11), as illustrated in FIG.1.

[0028] Coming back to FIG.1, the balancing plates (6, 7) features two planar portions wherein a uniform mass is distributed by removing or adding mass on these plates (6, 7), in singular or plural instances, along the surfaces in the plane. However, the locking nut mechanism (5) depicted in FIG.1 may encounter loosening problems while rotation of the rotor. The magnet holder comprises an axial boss and hole feature for engaging with the rotor shaft (14) preferably by an interference or adhesive mechanism or combination of apparent methods. Coaxially the magnetic signal is electrically converted by the sensor (not shown here) which is placed over the circuit board (not shown here) coaxial to the rotor axis. From the current design mentioned above, it is to be understood that many other possible modification and variations can be made without departing from scope of sensing & it is therefore contemplated and current invention with appended claims will cover such modification and constructions with variations that fall within the scope of invention.

[0029] The present invention proposes a preferred embodiment of a permanent integrated magnet structure for rotating devices, such as torque producing rotating devices. The structure comprises a magnet holding body as shown in FIG. 3, configured to secure a magnet (23) along a central axis vertical to a sensor PCB (21). The sensor PCB (21) is arranged/positioned at a predetermined distance from the housing (22), which encases the rotating device within a liquid medium.

[0030] Coming back to FIG.3, the structure incorporates a rotor shaft (25) housing torque producing magnets within the rotor, arranged to align in line with the structure. The rotor additionally accommodates current-carrying coils wound in single or multiple configurations over a ferrous core. This arrangement enhances the efficiency and functionality of the device.
[0031] Moreover, the rotor shaft (25) serves as an embodiment of the present invention which integrates both the magnet structure and the balancing structure, as seen in FIGS. 3 and 4. This integration reduces the overall size of the device, eliminates the need for extensive locking nut and extended shaft lengths, resulting in a more compact and versatile device suitable for both simply supported and overhung or cantilever-type rotor assemblies.

[0032] According to an embodiment of the present invention, FIG.4 illustrates a detailed view of the integrated magnet holder (28) on the rotor shaft (25). It is further illustrated in FIG.4, that the integrated magnet holder (28) holds/secures the magnets (23) in the area (29) at the top of rotor as seen in FIG.5. These magnets serve the purpose of facilitating rotating angle position sensing or rotating encoding purposes. According to the present invention, these magnets, face towards the sensor PCB (21), where the PCB houses hall effect sensor or optical sensors, serving similar functions.

[0033] FIG.5 further illustrates the balancing plate (24) that is integrated within the integrated magnet holder (28) for balancing the rotating motion of the rotor, in accordance with the present invention. Generally, an unbalance in a rotor occurs as a result of an uneven distribution of mass, which ultimately causes the rotor to vibrate. However, the balancing of rotors with the balancing plates (24) integrated within the integrated magnet holder (28) is instrumental in preventing the excessive bearing loads and preventing fatigue failure.

[0034] FIG.6 presents an alternative variation of the integrated magnet holder configuration. This embodiment includes an internal arrangement within the shaft (25), allowing for the passage of a coolant flow within a coolant channel (26, 26’). This feature facilitates the flow of a cooling fluid or medium for heat dissipation during rotation of the rotor, alongside the integrated magnet holder (28) and balancing plates (24). FIG. 7 further illustrates an exploded view of magnet (23), magnet holder (28) with balancing plate (24) and coolant channel in shaft (26) as well as a coolant channel (26’) through the magnet holder (28), according to an embodiment of the present invention. This feature enhances the thermal management of the system, ensuring efficient heat removal to maintain optimal operating conditions during rotation.

[0035] The present invention, therefore, incorporates a balancing plate within the magnet holder of a rotor to mitigate its rotational motion. This integration further necessitates the careful selection of materials capable of minimizing inertia and preventing magnetic flux dissipation. Non-ferrous options such as aluminum prove advantageous due to their lower density, which facilitates easier mass balancing during manufacturing. While alternative materials may also suffice, aluminum stands out as a prime example of a material effectively employed for this purpose in enhancing the functionality and efficiency of the system.

[0036] A compact and easily balanced rotor arrangement featuring an integrated magnet holder and balancing plate is disclosed here. This innovative design facilitates simplified manufacturing processes, reduces cycle time, and minimizes the number of components required, resulting in a more streamlined motor package.

[0037] Moreover, this design enhances adaptability and ease of assembly, making it highly efficient in various applications. By integrating the magnet holder and balancing plate, the invention not only ensures improved balance during operation but also contributes to a more compact overall motor design. This amalgamation of features not only enhances performance but also simplifies the manufacturing and assembly processes, offering a versatile and efficient solution for rotating devices.

[0038] The invention is not limited only to the embodiments described above and shown in the drawings, which primarily have an illustrative and exemplifying purpose. This patent application is intended to cover all adjustments and variants of the preferred embodiments described herein; thus, the present invention is defined by the wording of the appended claims and the equivalents thereof. Thus, the equipment may be modified in all kinds of ways within the scope of the appended claims.
,CLAIMS:I/ WE CLAIM:
1. A rotating device, comprising:
a) a rotor (11) and a stator (10) arranged inside a housing (22); and
b) a rotor shaft (25) positioned along a central axis, within the rotor (11);
wherein the rotor shaft (25) comprises
an integrated magnet holder (28) and a balancing plate (24) integrated with the magnet holder (28), to balance the rotating motion of the rotor (11).
.
2. The rotating device as claimed in claim 1, wherein the integrated magnet holder (28) is configured to secure a plurality of magnets (23) atop the rotor (11) in the central axis.

3. The rotating device as claimed in claim 1, wherein the integrated magnet holder (28) facilitates a rotating angle position sensing or an encoding purposes.

4. The rotating device as claimed in claim 1, wherein the magnets (23) in the integrated magnet holder (28) are oriented perpendicular to a sensor PCB (21) positioned at a predetermined distance from the housing (22), wherein the sensor PCB (21) is configured to detect a position or rotation of the rotor (11).

5. The rotating device as claimed in claim1, wherein the PCB is a hall sensor or an optical sensor.

6. The rotating device as claimed in claim1, wherein the rotor shaft (25) and the integrated magnet holder (28) comprise an internal coolant channel (26, 26’) to facilitate the flow of a cooling medium, for heat dissipation.

7. The rotating device as claimed in claim1, wherein the integrated magnet holder (28) and balancing plate (24) are made of non-ferrous materials, such as Aluminum.

8. The rotating device as claimed in claim 1, wherein the device is a simply supported motor assembly, an overhang motor assembly or a cantilever type rotor assembly.

9. The rotating device as claimed in claim 1, wherein the housing (22) encases the rotating device in a liquid medium.