Quick-drop motor assembly mask

Abstract

A mask for assembly of an electric motor is provided. The mask includes a body including slots configured to receive magnets and arranged in a sheath array, the sheath array being configured to correspond to a motor array of magnet-receiving slots of an electric motor core stack; a guard movably coupled to the body, the guard comprising slots arranged in a guard array corresponding to the sheath array. The guard is configured such that, in a first position, the slots of the guard array are at least partially misaligned with the slots of the sheath array, and such that, in a second position, the slots of the guard array align with the slots of the sheath array. The mask also includes a locator configured to locate a predetermined point of the electric motor core stack to position the sheath array in alignment with the motor array.

Description

QUICK-DROP MOTOR ASSEMBLY MASKFIELD

[0001] The present invention is directed to a mask for aiding assembly of an electric motor including magnets.BACKGROUND

[0002] The change from traditional internal combustion engines over to electrified vehicles is a global trend that is expected to continue. Regardless of any specific type of predominant future energy source (e.g., grid charged electric batteries or hydrogen fuel cell), electric motors are expected to be utilized with those energy sources, and permanent magnet motors appear to be a front runner technology. The assembly of permanent magnets into a motor core is typically done with robots or machine toolings inserting one magnet at a time. For electric motors including multiple hundreds of magnets per motor (e.g., between 200 and 300 permanent magnets for a typical passenger vehicle motor) ,over multiple core stacks, the assembly process can be time consuming and costly. More specifically, the current assembly approach for installing magnets into a core typically involves a robotic tool or a tooling on a Cartesian slide (with or without a w-axis to accommodate for different w-positions) picking a magnet from a feeder system and placing it into a slot in the rotor core. With several hundreds of magnets per rotor, current processes may render high volume production infeasible.SUMMARY

[0003] In some examples, the present disclosure is directed to a mask for aiding the assembly of an electric motor by accurately inserting multiple magnets into an electric motor core stack simultaneously. For instance, the magnets in an electric motor are often arranged in a specific pattern (e.g., an array), based on many different factors such as the type of motor (e.g., interior permanent magnet motors, synchronous assisted motors)) or generally advantageous magnetic field alignments applicable to different types of motor. Additionally, an electric motor is often constructed out of multiple core stacks (e.g., lamination stacks), and each core stack may require permanent magnets to be provided before assembly into the final electric motor. To aid this process, a mask can be used that has the same array of magnets as the electric motor core stack. This array of the mask can be filed with magnets, and a guard canbe positioned over the array to help retain the magnets. The mask can then be positioned to align the array of the mask with the array of the electric motor core stack, and the guard can be released, inserting (e.g., dropping) every magnet into the core stack simultaneously. The mask can then be exchanged with another mask already filled with magnets, and another core stack can be filled with magnets from the second mask while the first mask is being refilled with magnets. The mask can, therefore, aid in the assembly of an electric motor.

[0004] In a first aspect, the present disclose provides a mask for assembly of an electric motor. The mask includes a body including slots configured to receive magnets and arranged in a sheath array, the sheath array being configured to correspond to a motor array of magnetreceiving slots of an electric motor core stack; a guard movably coupled to the body, the guard comprising slots arranged in a guard array corresponding to the sheath array. The guard is configured such that, in a first position, the slots of the guard array are at least partially misaligned with the slots of the sheath array, and such that, in a second position, the slots of the guard array align with the slots of the sheath array. The mask also includes a locator configured to locate a predetermined point of the electric motor core stack to position the sheath array in alignment with the motor array.

[0005] In a second aspect according to the first aspect, the mask further comprises at least one tooling structure configured to interface with a robotic element. The at least one tooling structure is positioned to correspond to at least one predetermined component of the robotic element.

[0006] In a third aspect according to the first and / or second aspect, the guard is biased to the first position, and the guard is configured to receive an applied actuation force to counter the bias and move the guard into the second position.

[0007] In a fourth aspect according to any of the first through third aspects, the guard is configured to rotate from the first position to the second position based on the applied actuation force.

[0008] In a fifth aspect according to any of the first through fourth aspects, the guard is configured to translate from the first position to the second position based on the applied actuation force.

[0009] In a sixth aspect according to any of the first through fifth aspects, the locator comprises a projection away from the body, and the locator is further configured to contact the predetermined point when the mask is positioned above the electric motor core stack.

[0010] In a seventh aspect according to any of the first through sixth aspects, the magnets comprise a plurality of permanent magnets, and wherein the slots of the sheath array are configured to be at least as half as tall as the permanent magnets the slots of the sheath array are configured to receive.

[0011] In an eighth aspect according to any of the first through seventh aspects, the mask further comprises a clearing force applicator configured to apply a clearing force in the slots of the sheath array when the guard is in the second position.

[0012] In a ninth aspect according to any of the first through eighth aspects, the clearing force application comprises a plurality of retractable pins configured to apply the clearing force by inserting through the slots of the sheath array.

[0013] In a tenth aspect according to any of the first through ninth aspects, the slots of the guard array are configured to receive the plurality of retractable pins, and the guard, in a third position between the first position and the second position, is configured to contact a side of the retractable pins inserted through the slots of the sheath array and the slots of the guard array.

[0014] In an eleventh aspect according to any of the first through tenth aspects, the clearing force applicator comprises a pressurized fluid applicator configured to apply the pressurized fluid through the slots of the sheath array.

[0015] In a twelfth aspect according to any of the first through eleventh aspects, the body comprises a polymer material, and the body was produced using additive manufacturing.

[0016] In a thirteenth aspect, a method for assembly of an electric motor is provided. The method comprises obtaining a mask comprising a guard, a locator, and a body comprising slots containing magnets arranged in a sheath array; positioning the mask over slots of an electric motor core stack arranged in a motor array to align the sheath array with the motor array by using a locator of the mask, the positioning being based on contacting a predetermined contact point of the core stack with the locator; and actuating the guard of the mask from a first position to a second position causing at least one of the magnets to exit from the slots of the sheath array into the slots of the motor array.

[0017] In a fourteenth aspect according to the thirteenth aspect, positioning the mask further comprises: gripping, by a robotic element, the mask at a predetermined point on the mask; positioning, by the robotic element, the mask over the core stack; and actuating, by the robotic element, the guard of the mask causing slots of a guard array of the guard to align with the sheath array.

[0018] In a fifteenth aspect according to the thirteenth and / or fourteenth aspect, the method further comprises: inserting, while the guard is in the second position, retractable pins through each slot of the sheath array causing a remaining magnet in the slots of the sheath array to exit from the slots of the sheath through the slots of the guard array by applying a clearing force to the remaining magnet.

[0019] In a sixteenth aspect according to any of the thirteenth through fifteenth aspects, the method further comprises: inserting, while the guard is in the second position, the retractable pins through each slot of the sheath array and each slot of the guard array; and returning the guard towards the first position while the retractable pins are being retracted through the slots of the guard array.

[0020] In a seventeenth aspect according to any of the thirteenth through sixteenth aspects, the method further comprises: after actuating the guard of the mask from a first position to a second position, positioning, by a robotic element, the mask at a second location; depositing, by the robotic element, the mask at the second location; obtaining, by the robotic element, a second mask comprising a second guard, a second locator, and second slots containing magnets arranged in a second sheath array; and positioning, by the robotic element, the second mask over second slots of a second electric motor core stack arranged in the motor array to align the sheath array with the motor array.

[0021] In an eighteenth aspect according to any of the thirteenth through seventeenth aspects, obtaining the mask further comprises printing the guard and the body using additive manufacturing.

[0022] In a nineteenth aspects, a system for assembly of an electric motor is provided. The system includes a mask, the mask comprising: a body comprising slots configured to receive magnets and arranged in a sheath array, the sheath array being configured to correspond to a motor array of magnet-receiving slots of an electric motor core stack; a guard movably coupled to the body, the guard comprising slots arranged in a guard array corresponding to the sheath array, wherein the guard is configured such that, in a first position, the slots of the guard array are at least partially misaligned with the slots of the sheath array, and such that, in a second position, the slots of the guard array align with the slots of the sheath array; and a locator configured to locate a predetermined point of the electric motor core stack to position the sheath array in alignment with the motor array, and a robotic element. The robotic element comprises: an end of arm tool (EOAT) configured to fixedly interface with the mask, and componentsmovable relative to each other, the components configured to provide for movement of the mask fixedly interfaced with the EAOT from a first location to a second location.

[0023] In a twentieth aspect according to the nineteenth aspect, the system further comprises: an electric motor core stack, the electric motor core stack comprising: laminations for an electric motor, the laminations comprising a motor array of slots configured to receive magnets, wherein the motor array matches the sheath array.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Subject matter of the present disclosure will be described in even greater detail below based on the exemplary figures. All features described and / or illustrated herein can be used alone or combined in different combinations. The features and advantages of various embodiments will become apparent by reading the following detailed description with reference to the attached drawings, which illustrate the following:

[0025] Fig. 1A illustrates an example of a back side of a mask including a first array according to an embodiment of the present disclosure;

[0026] Fig. IB illustrates an example of a front side of a mask including the first array according to an embodiment of the present disclosure;

[0027] Fig. 2A illustrates an example of a back side of a mask including a second array according to an embodiment of the present disclosure;

[0028] Fig. 2B illustrates an example of a front side of a mask including the second array according to an embodiment of the present disclosure

[0029] Fig. 3A illustrates an example of a back side of an assembled mask including the second array according to an embodiment of the present disclosure;

[0030] Fig. 3B illustrates an example of a front side of the assembled mask including the second array according to an embodiment of the present disclosure;

[0031] Figs. 4A - B illustrate an example of the movement of a guard of the assembled mask from a first position to a second position according to an embodiment of the present disclosure;

[0032] Fig. 5A is a perspective view of an example of a back side of a mask coupled to a robotic end of arm tool (EOAT) according to an embodiment of the present disclosure;

[0033] Fig. 5B is a perspective view of an example of a front side of the mask coupled to the EOAT of a robotic element according to an embodiment of the present disclosure; and

[0034] Fig. 6 illustrates an example of a robotic element manipulating and utilizing a mask to insert magnets into an electric motor core according to an embodiment of the present disclosure.DETAILED DESCRIPTION

[0035] Examples of the presented application will now be described more fully hereinafter with reference to the accompanying Figs., in which some, but not all, examples of the application are shown. Indeed, the application may be exemplified in different forms and should not be construed as limited to the examples set forth herein; rather, these examples are provided so that the application will satisfy applicable legal requirements. Where possible, any terms expressed in the singular form herein are meant to also include the plural form and vice versa, unless explicitly stated otherwise. Also, as used herein, the term “a” and / or “an” shall mean “one or more” even though the phrase “one or more” is also used herein. Furthermore, when it is said herein that something is “based on” something else, it may be based on one or more other things as well. In other words, unless expressly indicated otherwise, as used herein “based on” means “based at least in part on” or “based at least partially on”.

[0036] The present disclosure provides for many advantages and improvements. For example, embodiments of the present disclosure can allow for drastically increased (e.g., by a factor of 3x to lOx) throughput of filling electric motor core stacks with magnetic material (e.g., magnets) because, whereas a single motion of a robotic element previously may have resulted in only a single magnet being inserted into the core stack, the present disclosure enables a single motion of a robotic element to fill every magnet slot in an entire core stack at one time. Accordingly, throughput can be increased proportionally to the number of magnets utilized by the electric motor. Additionally, the manufacturing footprint (e.g., number of stations in the manufacturing process and / or square footage of surface area required) can be reduced because fewer motions and components are needed to fill an electric motor core stack. Moreover, the mask can be made of cost-effective materials and be adaptable to any shape, size, or array, allowing for flexible and almost universal applications.

[0037] In an example embodiment, the mask (e.g., the quick-drop mask) can be a container holding several magnets in the correct position which can be released at the correct time. For example, rather than handling every single magnet, the mask can place (e.g., provide, insert) an entire layer of magnets to a motor core with a single motion. To do that, a robotic elementcan grab a mask already filled with the correct magnets. The robotic element can position the mask above the electric motor core (e.g., an electric motor rotor), lower it under the use of press force monitoring into certain details of the electric motor core (e.g., to ensure ideal lineup between the motor core and the mask) and activate a release mechanism (e.g., by pulling and / or pushing on a small lever or contact) which causes a guard (e.g., a disc) mounted on the bottom of the mask to rotate (e.g., 5-10 degrees). That rotation of the disc can open a pathway for the magnets to drop into the core (e.g., under the force of gravity). In addition, a tooling (e.g., actuatable cylinders) can lower through the top openings of the mask, slightly pushing on each magnet to ensure they fully slip into the core unless that already happened due to gravity alone. The mask can be used in high volume assembly processes, which is an environment where the product designs are typically finalized. Embodiments of the present disclosure can therefore enable a significant gain in throughput capability compared to currently used automations for this assembly process. Additionally, and / or alternatively, a mask can also be used as a manual tool to assist an operator inserting magnets into a motor core as a backup or offline low volume build. For example, the mask can have chamfers to help facilitate a person inserting magnets rather than trying to hit a tight slot in an e-rotor core segment. The mask can then be filled in parallel to an operator loading a motor core to reduce a production cycle time just as in high production cycles and / or when used in conjunction with a robotic element.

[0038] With regards to the materials and composition of at least portions of the mask, traditional machining with high strength materials is possible. Additionally, and / or alternatively, wear and tear on the mask could be minimal, providing for a manufacturing process of the mask using additive manufacturing (e.g., 3D-printing). Additionally, and / or alternatively, the mask can be made of various materials chosen based on the intended specific application for the mask and environment of the assembly program. For instance, the mask can include a surface coating in order to modify material characteristics like friction, chemical resistance, heat resistance, and durability to allow the mask to operate at high speed, high temperature, and / or in corrosive environments. Additionally, and / or alternatively, slots of the mask can be surface coated to reduce friction, thereby improving the chances of a magnet exiting the mask without needing to apply a clearing force.

[0039] A manufacturing process of the mask using additive manufacturing can provide a very cost-effective way of tooling the mask to a specific application, while enabling a fast response time to any changes, regardless of whether they are due to changes in the customer part, a technical reason requiring any changes, or by adding a theoretically unlimited modelcomplexity in the same machine simply by using a different mask. Another aspect that can help provide adaptability of a base mask to a specific application is that a number of masks of a single program (e.g., an assembly program) can share common contact points for resting in the pre-fill apparatus (e.g., the apparatus that fills the mask with magnets before the mask is picked up by the robotic element) and can have common pickup points for the robot or machine tooling, allowing for the same robot EOAT and machine tooling to pick up every mask designed within this program. Moreover, the masks can be easily managed within inventories, for example, because each mask can also have a machine readable means of identification for tracking and handling purposes.

[0040] Figs. 1A and IB provide an example of a quick-drop mask 100 with a sheath array 102 according to an embodiment of the present disclosure. The mask 100 includes a body 114 including slots 104 configured to receive magnets arranged in a sheath array 102. The sheath array can be configured to correspond to a motor array of magnet-receiving slots of an electric motor core stack. The sheath array 102 is the arrangement (e.g., pattern, layout) of the slots 104 within the body 114 which receive the magnetic material (e.g., permanent magnets) for the electric motor (e.g., act as sheaths for the magnets). For instance, in Figs. 1 A and IB, the slots 104 of mask 100 are arranged radially, and as a result, the sheath array 102 is an arrangement of radially aligned slots 104. Therefore, when the sheath array 102 aligns with (e.g., matches up to) a corresponding array of an electric motor core stack, slots 104 will align with the slots of the electric motor core stack. Additionally, when the sheath array 102 and / or the array of a core stack are radially symmetrical, many different orientations of the mask 100 relative to the core stack may achieve an alignment of the two arrays, and therefore, and alignment of slots 104 with the slots of the electric more core stack.

[0041] The mask can also include at least one tooling structure 112 configured to interface with a robotic element, where the at least one tooling structure 112 is positioned to correspond to at least one predetermined component of the robotic element. For instance, a tooling structure 112 can be used to engage and couple with the robotic element (e.g., the robotic EOAT of the robotic element). Using tooling structure 112, the robotic element may manipulate (e.g., move, position) mask 100 from a pre-fill apparatus, to the electric motor core stack, to a specific position with respect to the core stack (e.g., above, with sheath 102 aligned with the core stack array), and manipulate the mask 100 to a further position (e.g., back to the pre-fill apparatus to be filed for further use or another station which receives the mask 100).

[0042] Fig. 1A depicts a back side of the mask 100, referring to the side of the mask 100 that faces the robotic element and / or robot EOAT when coupled to the robotic element. In contrast, Fig. IB depicts a front side, (e.g., a face), referring to the side of the mask 100 that faces away from the robotic element and / or the robot EOAT when coupled to the robotic element, and toward the electric motor core stack when the mask 100 is positioned above the core stack. As shown in Fig. IB, the mask 100 also includes a guard 106 movably coupled to the body 114. The guard 106 includes slots 110 arranged in a guard array 108 corresponding to the sheath array 102. The guard 106 is configured such that, in a first position, the slots 110 of the guard array 108 are at least partially misaligned with the slots 104 of the sheath array 102, and such that, in a second position, the slots 110 of the guard array 108 align with the slots 104 of the sheath array 102. In Fig. IB, the guard array 108 is depicted in alignment with the sheath array 102, such that slots 110 are aligned with slots 104. However, the guard 106 can be actuated to rotate and / or translate such that the slots 110 and the slots 104 are not in alignment (e.g., are misaligned). When the guard array 108 and the sheath array 102 are not aligned, the guard can at least partially overlap the slots 104 and prevent any material in the slots 104 from exiting the mask 100 from the front side. This actuation of the guard 106 can occur, at least in part, due to the actuation channels 116, which can receive a fastener (e.g., screw, pin, rivet) around which the channels 116 move to provide the rotation and / or translation.

[0043] Figs. 2A and 2B provide another example of a quick-drop mask 200 with a sheath array 202 according to an embodiment of the present disclosure. Similar to the mask 100, the mask 200 includes a body 214 including slots 204 arranged in an array 202, where the slots 204 each sheath (e.g., retain, contain, hold) magnetic material (e.g., a single continuous permanent magnet). Also similar to the mask 100, mask 200 includes a guard 206 with slots 210 arranged in a guard array 208, and actuation channels 216, which perform the same function as channels 116 and a tooling structure 212 which performs the same function as tooling structure 112. However, the sheath array 202 and guard array 208 are different arrays (e.g., their slots are arranged differently) than their respective counterparts of mask 100, the sheath array 102 and guard array 108. Therefore, a mask can have a different array for the sheath array 202 and / or guard array 208 but retain the same proportions, composition, and other features (e.g., standardized proportions for a single program), allowing for use with multiple different electric motors. For example, between two masks, mask 100 and mask 200, the tooling structure 212 can be the same as 112, the mask 200 can be the same size and proportionsas mask 100 requiring no adjustment of the robotic EOAT, and the actuation mechanism for the guard 206 can be the same as the guard 106. In this case, the mask can enable a single robotic element to construct multiple different types of electric motors having different arrangements, without loss of throughput, by exchanging one mask with a first array for a second mask with a second array, because the robotic element may be agnostic to any change in the mask (e.g., because the components the robotic element interacts may not have changed).

[0044] While two arrays are shown, the masks 100 and / or 200 can support an almost infinite number of sheath and / or guard arrays. For instance, almost any cross section of an array of an electric more stack can be reproduced in the mask, allowing for arrays of an almost infinite number of different arrangements of slots. Furthermore, if an array is too large, complex, or densely packed (e.g., the magnets require close placement) for one mask, a another mask can be quickly produced to provide an array that, used in conjunction with another array, achieves the appropriate array and the appropriate face and / or body size and an accurate placement of magnets in an electric motor array. Additionally, and / or alternatively, multiple masks may be used to fill a single core stack for more complex arrays, for example, when the core stack includes different arrays at different depths and / or the core stack has slots of an array with a depth greater than the height of the magnets received by the slots of a single mask. Additionally, and / or alternatively, the slots arranged in an array may be any shape (e.g., rectangular, circular, octagonal).

[0045] Fig. 3 A provides an example of a back side of an assembled mask 300 according to an embodiment of the present disclosure with an array 302 similar to the array 202 of mask 200. The mask 300 includes curvilinear slots 304 configured to receive a plurality of magnets (e.g., one magnet in each slot 304) with a height equal to the height 318 (e.g., thickness) of the mask 300. Additionally, and / or alternatively, the slots 304 can be as tall as the intended magnets and / or a sufficient height of the magnet (e.g., half as tall as the height of the magnets). The height 318 can be taller than or the same height as a corresponding motor core stack, in which case magnets received by the slots 304 (where the magnets are the same height as the height of the slots of the core stack) can be completely secured within the body 314 of the mask 300, providing for protection of the magnets during movement of the mask 300 and protection against loss of magnets (e.g., magnets exiting the slots 304 before mask 300 is appropriately positioned) caused by inertial forces acting on the magnets during movement of the mask 300. Guard 306 also includes contacts 320 which can receive an actuation force to rotate and / or translate guard 306 relative to the body 314 of mask 300.

[0046] Fig. 3B provides an example of a front side of the assembled mask 300 with an actuation system according to an embodiment of the present disclosure. For instance, mask 300 includes a guard 306 which includes curvilinear slots 310 arranged in a guard array 308 and a tooling structure 312 for engaging (e.g., coupling) with a robotic element (e.g., a robotic EOAT for a robotic element). Additionally, and / or alternatively, a guard (e.g., guard 306) can be placed on the back side of the mask 300 to assist in retention of the magnets in slots 304, wherein a guard 306 on the back side can be actuated to align a guard array with a sheath array 302 when receiving magnets in slots 304 and a guard 306 on the front side can be actuated to align a guard array 308 with the sheath array 302 when depositing (e.g., providing) magnets in the electric motor core stack. Mask 300 can also include studs 334 that can aid the positioning of the mask 300 with respect to other structures or stations in the electric motor assembly process (e.g., with respect to single or multiple of fixtures that provide a mask holder and / or staging area from which a robotic element picks up the mask). For example, a mask stand can have conically shaped locator pins that interface with the studs 334 (e.g., the insert into the hollow portion of studs 334) and help ensure that, when the mask 300 is lowered onto the mask holder and / or stand, studs 334 force the mask 300 into the same location with respect to the mask holder and / or stand.

[0047] Mask 300 can include one or more rough locators 336. The rough locators 336 can be used to locate a predetermined point of the electric motor core stack to position the sheath array in alignment with the motor array. For instance, the rough locators 336 can contact a specific location on the core stack corresponding to a known location of the core stack. The rough locator 336 can include a projection away from the body 314, and the locator can be further configured to contact the predetermined point when the mask 300 is positioned above the electric motor core stack. Additionally, and / or alternatively, rough locators 336 may include light sources that are used to locate the mask 300 with respect to the core stack. For example, the light sources of rough locators 336 can shine continuously, and upon the emitted light contacting the motor core, a vision system can detect that the light signature has changed (e.g., by contacting a reflective surface specifically positioned on the core stack and increasing the light signature or by motor core absorbing the emitted light and decreasing a light signature). The robotic element can then perform positioning of the mask 300 relative to the core stack based on the changing signature.

[0048] Mask can also include a fine locator 338 that is differently structured (e.g., smaller and / or differently shaped) than the rough locators 336 and / or differently positioned than roughlocators 336. For instance, the fine locator 338 can also be used to contact a different specific location or corresponding structure on the core stack, such as a receiving section (e.g., hole, channel, enclave in the laminations) and / or receiving structure of the core stack (e.g., a protrusion or indicator). The fine locator 338 can allow for more refined positioning than the rough locators 336.

[0049] The guard 306 can be movably coupled (e.g., fastened) to the body 314 using fasteners 324 provided in the actuation channels 316. For instance, the fasteners 324 (e.g., a pin, screw, rivet) may have a portion within the actuation channel 316 with a width smaller than the width of the actuation channel 316 and a portion above and / or below the actuation channel 316 with a width larger than the width of the actuation channel 316, acting as a retaining lip. The fastener 324 may then be able to stay in one position while the guard 306 is moved (e.g., rotated and / or translated), resulting in the actuation channels 316 moving around the fastener 324 while still remaining coupled to the body 314. To assist in movably coupling the guard 306 to the body 314, the guard 306 can include contacts 320, and a receiver 328 can be fixed to the guard 306. The receiver 328 can be secured (e.g., coupled) to a spring 330, and the spring 330 can be secured to an actuation anchor 332 (e.g., a pin fixed to the body 314). Moreover, the receiver 328 can be fixed to the guard 306 such that a force exerted on the receiver 328 is transferred to the guard 306. For example, spring 330 can be coupled to the receiver 328, and exert a restoring force (e.g., pull) on the receiver 328 when the receiver 328 is moved away from the actuation anchor 332. The force exerted by the spring 330 can then be transferred to the guard 306, such that when the spring 330 pulls the receiver back towards the actuation anchor 332, the spring 330 pulls the guard 306 back to a first position. While a spring 330 is shown providing the restoring force, other options may also be employed, such as employing magnetic forces and / or other mechanical tension forces.

[0050] Figs. 4A and 4B provide an example of an actuation system providing for movement (e.g., displacement, rotation, translation) of the guard 306 of mask 300. The guard 306 can be biased to a first position, and the guard 306 can be configured to receive an applied actuation force to counter the bias and move the guard 306 into a second position. The guard 306 can be configured to rotate and / or translate from the first position to the second position based on the applied actuation force. For example, Fig. 4A shows a first position of the guard 306, in which the guard array 308 is misaligned with the sheath array 302 (e.g., the slots 310 are offset with respect to slots 304). In the first position, the spring 330 is biasing the guard 306 into the first position by pulling the receiver 328 towards the actuation anchor 332. Theactuation channels 316 are each resting against their respective fasteners 324 at a first end of the actuation channel 316. By resting against the fasteners 324, the fasteners apply a normal force to the guard 306 which counters the bias force of the spring 330, achieving a stable first position. A force sufficient to overcome the bias force of the spring 330 may now be required to cause the guard 306 to rotate and / or translate.

[0051] A robotic element (e.g., via a robotic EOAT such as EOAT 540) can be used in with the mask 300 (e.g., as shown in Fig. 6). The robotic element can push or pull on a contact 320, and when the push or pulling force overcomes the bias force of spring 330, the robotic element can cause a rotation of the guard 306 from the first position to the second position. In other words, the spring 330 can keep the guard 306 in a closed position when in an offline condition (e.g., not being used by a robotic element). For instance, the force applied by the robotic element will cause the fasteners 324 to slide through the actuation channels 316 as the actuation channels move relative to the fixed fasteners 324. As the guard 306 rotates towards the second position, the spring 330 exerts an increasingly stronger restoring force on the receiver 328. The robotic element may be configured to push or pull the contacts 320 with a specified force based on the restoring force of the spring 330. For instance, the robotic element may apply a constant force to the contacts that causes the guard 306 to stop at the second position of Fig. 4B when the force applied by the robotic element is exactly countered by the restoring force of spring 330. Additionally, and / or alternatively, the robotic element may push or pull against the contacts 320 a predetermined distance to cause more controlled rotation. For instance, the robotic element can push on one contact 320 and / or pull on the other contact 320 causing a rotation of guard 306 (e.g., from 5 to 10 degrees of rotation of guard 306 to any other suitable degree of rotation that causes the guard 306 to move from a first, misaligned position to a second aligned position). Additionally, and / or alternatively, the robotic element may push or pull against the against contacts 320 to cause the guard 306 to translate in any direction (e.g., upwards from the actuation anchor 332 and / or side to side with respect to the actuation anchor 332 and / or slots of the sheath array 302).

[0052] Once the guard 306 has moved to the second position of Fig. 4B relative to the body 314, magnets contained in the body 314 can exit the slots 304 of the sheath array 302 (e.g., drop from the slots 304 into corresponding slots of the electric motor core stack. The guard 306 may then be moved back to the first position, partially or completely overlapping the slot 304 of sheath array 302 and prohibiting or obstructing a magnet from exiting the slots 304. The guard 306 may be moved back to the first position by a force applied by the robotic element,without the assistance of an additional restoring force. Additionally, and / or alternatively, the guard 306 may be pulled back to the first position by spring 330 pulling on the receiver 320, with or without the aid of the robotic element. For example, the spring 330 can exert a linear restoring force resulting in counterclockwise motion of the guard 306 to pull the guard 306 back from the second position to the first position

[0053] Additionally, and / or alternatively, the guard 306 may be moved to a third position different from either the first or second position. For example, a first position of the guard 306 relative to the body 314 may be advantageous for retaining magnets in slots 304, a second position of the guard 306 relative to the body 314 may be advantageous for allowing the magnets to exit the slots 304, and a third position of the guard 306 relative to the body 314 may be advantageous for receiving magnets in the slots 304 and / or some other purpose. For instance, the guard 306 can be configured to, in a third position between the first position and the second position, contact sides of retractable pins 550 (e.g., pins 550 of Figs. 5A - B) inserted through the slots 310 of the guard array 308. This contact can occur while the retractable pins 550 are being retracted through the slots 310.

[0054] The movement of the guard 306 can be aided through use of a robotic EOAT 540 of a robotic element, as shown in Figs. 5A - B. For example, EOAT actuators 542 can extend outward from the EOAT surface 544 and / or contract towards the EOAT surface 544. By extending, the actuators 542 can exert a force on the contacts 520 of the mask 500 to cause a movement of the guard 506 (e.g., push on the contacts 520 causing movement of the guard 506 similarly to movement of guard 306). Additionally, and / or alternatively, the actuators 542 can be configured to pull on the contacts 520 by contracting and pulling the contacts 520 towards EOAT surface 544 (e.g., by adhesive or magnetic coupling to contacts 520). For example, the two actuators 542 (one on each side pushing against and / or pulling on contacts 520 can serve two different functions. One actuator can be responsible for opening the guard 506 (or moving it into the second position), while the other actuator can be responsible for closing the guard 506 (moving it back to the first position). For instance, with reference to mask 300 of Fig. 4A shown from below in a closed position (e.g., a first position) the right hand EOAT actuator 542 could be pushed to open the guard 306 of mask 300 (e.g., move it to the second position), and when returned the spring 330 pulls back on the guard 306 and the left hand EOAT actuator 542 can push on the contacts (e.g., contacts 320) to make sure the guard 306 of mask 300 is closed (e.g., in the first position).

[0055] The robotic EOAT 540 may also couple to the mask 500 using tooling structure 512. The tooling structure 512 may interface with hitch 546 such that hitch 546 receives tooling structure 512. Once coupled to the hitch 546 using tooling structure 512, the mask 500 can be fixed or substantially fixed to the robotic EOAT 540 such that the robotic EOAT 540 and mask 500 experience the same inertial forces during movement (e.g., in contrast to a loose connection where the mask jiggles or has slack). This can advantageously result in less jostling of the components of the mask and aid retention of the magnets in the slots 504 of the body 514 of mask 500. Moreover, the tooling structure 512 can be standardized and uniform across different masks with different arrays and dimensions, allowing adaptability and exchangeability of masks within a program. Additional stability supports 548 of the EOAT can abut the back side of mask 500 (e.g., with rubber or polymer stoppers 552) to ensure accurate positioning of the mask with respect to the EOAT 540 and to reduce any jostling of the mask 500 (e.g., during movement by the EOAT 540 of the mask 500 to and from the electric motor core stack).

[0056] Upon the guard 506 moving from a first position to a second position (e.g., due to actuators 542 applying force), the magnets should exit from the slots 504 through the slots 510 of the guard array 508 (e.g., due to gravity when the mask 500 is positioned over an electric motor core stack). However, some magnets may remain in the slots 504 and / or 510 (e.g., get stuck). To assist the magnets in exiting the slots 504 and / or 510, a clearing force applicator can be configured to apply a clearing force in the slots 504 and / or 510 of the sheath array 502 when the guard 506 is in the second position. For example, the robotic EOAT 540 may use retractable pins 550 to push on the magnets and aid the magnets exit from the slots 504 and / or 510. The pins 550 (e.g., one pin for each slot 504) may be positioned above the back side of the mask 500, with sufficient clearance to allow for easy exchange of masks 500. When the mask 500 is positioned over the electric motor core stack and the guard 506 is actuated, the magnets should fall from the mask 500 into the corresponding slots of the electric motor core stack. The retractable pins 550, arranged in an array corresponding to the sheath 502 and guard array 508, can be extended by the robotic EOAT 540 into the slots 504 of the mask 500 and, additionally, can extend through the slots 510 of the guard 506. While being extended through the mask 500, the one or more of pins 550 can contact a magnet on the back side of the magnet (e.g., the side of the magnet opposite the side that is facing the electric core motor stack) and apply a clearing force (e.g., push on) to the magnet to clear it from the slots 504 and / or 510. The pins 550 can extend all the way through and / or up to the slots 510 of the guard 506 to help ensure the magnets are cleared, or may extend only a certain depth into the slots 504. After clearing oneor more magnets from the mask 500, the pins 550 can be retracted from the slots 504 and / or 510 of the mask 500 back to their original position above the back side of mask 500.

[0057] Additionally, and / or alternatively, other objects may be used to apply clearing forces. For example, the pins 550 can be the exact size and shape of the magnets received by slots 504, which can improve the clearing force application. Pressurized fluid can also be used instead of and / or with the pins 550. For example, the robotic EOAT 540 can blow pressurized air and / or cleaning solution from the back side of the mask 500 through the slots 504 and / or 510 of the mask 500 to blow the magnets out from the mask 500 and towards the electric motor core stack. The robotic EOAT 540 can employ this pressurized fluid in conjunction with the pins 550 (e.g., to provide additional clearing force and / or advantageous lubricants or cleaning solutions) or may employ pressurized fluid as the clearing force without also using the pins 550 (e.g., to reduce the number of moving components).

[0058] The clearing force (e.g., the use of the retractable pins 550 and / or a pressurized fluid applicators 554) may be applied automatically (e.g., as a rule, in conjunction with moving the guard from the first position to the second position) and / or may be applied in response to determining that a magnet remains in a slot 504 and / or 510 (e.g., using a vision system to detect whether all slots have been emptied). For instance, the EOAT 540 may be structured such that actuating the actuators 542 simultaneously depresses (e.g., extends) the retractable pins 550. Additionally, and / or alternatively, the pins 550 may be depressed into the slots 504 and / or 510 based on and / or in response to the guard 506 achieving the second position. Moreover, the pins 550 may be depressed into the slots 504 and / or 510 based on the vision system determining that less than all of the magnets have exited the mask 500 and / or that the slots of an electric motor core stack have not been completely filled with magnets. Additionally, the mask 500 may include an integrated means of part detection for each magnet for improved error handling or fault prevention. For example, each slot 504 and / or 510 can include a sensor or mechanical switch / spring that provides information relating to whether the magnet of that slot 504 and / or 510 has exited the respective slot.

[0059] Additionally, and / or alternatively, The EOAT 540 can also utilize the pressurized fluid applicators 554 to produce the clearing force. For example, an air distribution plate (e.g., similarly shaped as the mask 500) including the pressurized fluid applicators 554 can be mounted on the EOAT 540. The plate (e.g., produced via additive manufacturing) can be mounted inside the EOAT 540, where it would be positioned such that the mask 500, when getting picked up by the EOAT 540, can lay against this air distribution plate. The distributionplate can have openings (e.g., pressurized fluid applicators 554) pointing towards the slots 504 of the mask 500 (e.g., an applicator 554 for each of the magnet positions), and an embedded (e.g., internal) channel system connecting all applicators 554 to one common air connection. Therefore, pressurized fluid applicators 554 can provide a stationary (e.g., stationary relative to the EOAT 540) 'blow out' feature as the clearing force.

[0060] Additionally, and / or alternatively, the guard 506 can be configured to, in a third position between the first position and the second position of the guard 506, contact a side of the retractable pins 550 inserted through the slots 510 of the guard array 508. This contact can occur, for example, while the retractable pins 550 are being retracted through the slots 310 producing a stripping effect. The scraping effect provides the additional advantage that, if the magnets had any attractive force to the pins 550 (e.g., magnetism, adhesion, oily substances), the guard 506 can act as a stripper that strips the magnet from the pins 550 as pins 550 are retracted by scraping the pins 550 against the sides of slots 510. The stripping effect can be assisted by providing slots 510 with an additional enclave 311 such as shown in Figs. 4A - B. The enclave 311 can be any shape, and can additionally partially surround a pin 550 (e.g., a half-circle, triangle, rectangle) while also doubling as cooling passages. Additionally, and / or alternatively, the enclaves 311 can be provided on a same side of each slot 510.

[0061] Fig. 6 provides an example of a robotic element according to the present disclosure. The robotic element can include an EOAT configured to fixedly interface with the mask, and the components of the EOAT can include components movable relative to each other. The components can be configured to provide for movement of the mask fixedly interfaced with the EAOT from a first location to a second location. For instance, the robotic element 600 can include and operate a robotic EOAT 602, similar to the EOAT 540 of Figs. 5 A - B. The robotic element 600 is capable of moving and manipulating itself in space (e.g., using one or more electric motors 604) and can thereby manipulate (e.g., move) the mask 606. This movement can be achieved, for instance, by using a motor 604 to move arm 608 relative to leg 610 and / or arm 612 relative to base 614. The robotic element 600 can be used with mask 606 to deposit magnets into electric motor core stack 616.

[0062] The electric motor core stack 616 of Fig. 6 is made of laminations 618 for an electric motor, and the laminations 618 include a motor array 620 of slots configured to receive magnets matching the sheath array of mask 606. The core stack 616 can be a rotor and / or a stator of the electric motor that is configured to receive magnets. The electric motor formed with core stack 616 may utilize the magnets supplied by mask 606 in operation.

[0063] A process for assembling an electric motor can be performed using the robotic element 600 of Fig. 6. For example, the robotic element 600 can obtain the mask 606 including the guard 605, the locator 607, and the slots containing magnets 611 arranged in the sheath array. The robotic element 600 may obtain the mask 606 from a table, other station, and / or another robotic element. For instance, the mask 606 can be loaded with magnets 611 (e.g., receive magnets 611 in slots) at a pre-assembly station 630 that verifies that mask 606 is fully populated with magnets (e.g., a vision system can verify every slot of mask 606 has received a magnet 611). After filling the slots with magnets 611 (e.g., after every slot has received a magnet 611), the robotic element 600 can pick up the mask 606, for example my gripping the mask 606 and coupling the hitch 546 and tooling structure 512 as shown in Figs. 5 A - B.

[0064] The robotic element 600 may position the obtained mask 606 over slots of an electric motor core stack 616 arranged in a motor array 620 to align the sheath array with the motor array 620 by using a locator 607 of the mask 606 based on contacting a predetermined contact point of the core stack 616 with the locator 607. For instance, the robotic element 600 can move the obtained mask 606 from the pre-assembly station 630 over to the area of the core stack 616. This movement can be done at a high speed with less controlled movements. Once in the area of the core stack 616, the robotic element 600 can slow done and / or use more controlled movements (e.g., apply force control procedures) to position the mask 606 over the core stack 616.

[0065] The robotic element 600 can fine tune the exact position of the mask 606 over the core stack 616 by using a rough locator and a fine locator (e.g., locators 336 and 338 of mask 300). For example, the robotic element can use a rough locator to contact (e.g., bump) the core stack 616 to receive feedback indicating that the mask 606 is near the core stack 616. This feedback can be improved (e.g., made more sensitive) with the use of multiple rough locators at different positions on the mask 606, thereby providing more feedback about which portions of mask 606 are near and / or above core stack 616. After the rough locators have abutted the mask 606 at a specific location and / or predetermined contact point 626 (e.g., abutted a depression in the face of the core stack that partially receives the locator), the robotic element 600 can determine that the mask 606 is properly positioned. Additionally, and / or alternatively, the rough locator may not abut any specific position, but robotic element 600 can continue to move the mask until the fine locator contacts a specific position on the core stack 616. The fine locator can then contact a more specific location on the core stack 616 then the rough locator.

[0066] The robotic element 600 can then actuate the guard 605 of the mask 606 from a first position to a second position causing slots of a guard array 624 of the guard 605 to align with the sheath array, allowing for at least one of the magnets 611 to exit from the slots of the guard array 624 into the slots of the motor array 620. The core stack 616 can receive the magnets 611 from the mask 606 after the magnets exit the slots.

[0067] One of the advantages of the present disclosure is that a mask 606 can easily be exchanged with another mask loaded with magnets, allowing for rapid filling of electric motor core stacks. For instance, after actuating the guard of the mask from a first position to a second position, the robotic element can position the mask 606 at a second location (e.g., back at the pre-assembly station or another station). At this second location, the robotic element 600 can deposit the mask 606 (e.g., release the mask 606 from the robotic EOAT 602. The robotic element 600 can then obtain, from the second location where the mask 606 was deposited or from another location, a second mask identical or similar to the first mask 606 (e.g., having a second guard, a second locator, and second slots). This second mask can already be filled with magnets arranged in the same array as array 624. The robotic element 600 can then position the second mask over slots of a second electric motor core stack arranged in the motor array 620 to align the sheath array with the motor array 620, just like with the first mask. This exchangeability of the mask 606 can thus produce a rapidly repeatable process for supplying electric motor core stacks with magnets.

[0068] While subject matter of the present disclosure has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. Any statement made herein characterizing the invention is also to be considered illustrative or exemplary and not restrictive as the invention is defined by the claims. It will be understood that changes and modifications may be made, by those of ordinary skill in the art, within the scope of the following claims, which may include any combination of features from different embodiments described above.

[0069] The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article “a” or “the” in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of “or” should be interpreted as being inclusive, such that the recitation of “A or B” is not exclusive of “A and B,” unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of “at least one of A, B and C” should be interpreted as one or more of a group of elements consistingof A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. Moreover, the recitation of “A, B and / or C” or “at least one of A, B or C” should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B and C.

Claims

AMENDED CLAIMS received by the International Bureau on 17 April 2024 (17.04.2024)What is claimed is:

1. A mask for assembly of an electric motor, the mask comprising: a body comprising slots configured to receive magnets and arranged in a sheath array, the sheath array being configured to correspond to a motor array of magnet-receiving slots of an electric motor core stack; a guard movably coupled to the body, the guard comprising slots arranged in a guard array corresponding to the sheath array, wherein the guard is configured such that, in a first position, the slots of the guard array are at least partially misaligned with the slots of the sheath array, and such that, in a second position, the slots of the guard array align with the slots of the sheath array; and a locator configured to locate a predetermined point of the electric motor core stack to position the sheath array in alignment with the motor array.

2. The mask of claim 1, wherein the mask further comprises at least one tooling structure configured to interface with a robotic element, wherein the at least one tooling structure is positioned to correspond to at least one predetermined component of the robotic element.

3. The mask of claim 1, wherein the guard is biased to the first position, and the guard is configured to receive an applied actuation force to counter the bias and move the guard into the second position.

4. The mask of claim 3, wherein the guard is configured to rotate from the first position to the second position based on the applied actuation force.

5. The mask of claim 3, wherein the guard is configured to translate from the first position to the second position based on the applied actuation force.

6. The mask of claim 1, wherein the locator comprises a projection away from the body, and the locator is further configured to contact the predetermined point when the mask is positioned above the electric motor core stack.SUBSTITUTE SHEET (RULE 26)7. The mask of claim 1, wherein the magnets comprise a plurality of permanent magnets, and wherein the slots of the sheath array are configured to be at least as half as tall as the permanent magnets the slots of the sheath array are configured to receive.

8. The mask of claim 1, further comprising a clearing force applicator configured to apply a clearing force in the slots of the sheath array when the guard is in the second position.

9. The mask of claim 8, wherein the clearing force application comprises a plurality of retractable pins configured to apply the clearing force by inserting through the slots of the sheath array.

10. The mask of claim 9, wherein the slots of the guard array are configured to receive the plurality of retractable pins, and wherein the guard, in a third position between the first position and the second position, is configured to contact a side of the retractable pins inserted through the slots of the sheath array and the slots of the guard array.

11. The mask of claim 8, wherein the clearing force applicator comprises a pressurized fluid applicator configured to apply the pressurized fluid through the slots of the sheath array.

12. The mask of claim 1, wherein the body comprises a polymer material, and wherein the body was produced using additive manufacturing.

13. A method for assembly of an electric motor, the method comprising: obtaining a mask comprising a guard, a locator, and a body comprising slots containing magnets arranged in a sheath array; positioning the mask over slots of an electric motor core stack arranged in a motor array to align the sheath array with the motor array by using a locator of the mask, the positioning being based on contacting a predetermined contact point of the core stack with the locator; and actuating the guard of the mask from a first position to a second position causing at least one of the magnets to exit from the slots of the sheath array into the slots of the motor array.

14. The method of claim 13, wherein positioning the mask further comprises: gripping, by a robotic element, the mask at a predetermined point on the mask;SUBSTITUTE SHEET (RULE 26)positioning, by the robotic element, the mask over the core stack; and actuating, by the robotic element, the guard of the mask causing slots of a guard array of the guard to align with the sheath array.

15. The method of claim 13, further comprising: inserting, while the guard is in the second position, retractable pins through each slot of the sheath array causing a remaining magnet in the slots of the sheath array to exit from the slots of the sheath through the slots of the guard array by applying a clearing force to the remaining magnet.

16. The method of claim 15, further comprising: inserting, while the guard is in the second position, the retractable pins through each slot of the sheath array and each slot of the guard array; and returning the guard towards the first position while the retractable pins are being retracted through the slots of the guard array.

17. The method of claim 13, further comprising: after actuating the guard of the mask from a first position to a second position, positioning, by a robotic element, the mask at a second location; depositing, by the robotic element, the mask at the second location; obtaining, by the robotic element, a second mask comprising a second guard, a second locator, and second slots containing magnets arranged in a second sheath array; and positioning, by the robotic element, the second mask over second slots of a second electric motor core stack arranged in the motor array to align the sheath array with the motor array.

18. The method of claim 13, wherein obtaining the mask further comprises printing the guard and the body using additive manufacturing.

19. A system for assembly of an electric motor, the system comprising: a mask, the mask comprising: a body comprising slots configured to receive magnets and arranged in a sheath array, the sheath array being configured to correspond to a motor array of magnet-receiving slots of an electric motor core stack;SUBSTITUTE SHEET (RULE 26)a guard movably coupled to the body, the guard comprising slots arranged in a guard array corresponding to the sheath array, wherein the guard is configured such that, in a first position, the slots of the guard array are at least partially misaligned with the slots of the sheath array, and such that, in a second position, the slots of the guard array align with the slots of the sheath array; and a locator configured to locate a predetermined point of the electric motor core stack to position the sheath array in alignment with the motor array, and a robotic element, the robotic element comprising: an end of arm tool (EOAT) configured to fixedly interface with the mask, and components movable relative to each other, the components configured to provide for movement of the mask fixedly interfaced with the EAOT from a first location to a second location.

20. The system of claim 19, wherein the system further comprises: an electric motor core stack, the electric motor core stack comprising: laminations for an electric motor, the laminations comprising a motor array of slots configured to receive magnets, wherein the motor array matches the sheath array.

21. The mask of claim 1, wherein the mask comprises at least one of steel, brass, aluminum, or titanium, and wherein the mask was produced using machining manufacturing.

22. The method of claim 13, wherein obtaining the mask further comprises producing the mask using machining manufacturing, and wherein the mask comprises at least one of steel, brass, aluminum, or titanium.

23. The system of claim 19, wherein the mask comprises at least one of steel, brass, aluminum, or titanium, and wherein the mask was produced using machining manufacturing.

24. The mask of claim 1, further comprising an integrated means, integrated into the body of the mask, of detecting the presence of the magnets in the slots of the body.SUBSTITUTE SHEET (RULE 26)STATEMENT UNDER ARTICLE 19 (1)The differences between the claims as filed and the claims as amended are as follows: claims-20 remain unchanged; and new claims 21-24 added.(i) Basis for the amendment: support for the new claims 21-24 can be found in paragraphs [0036], [0038], and [0058] of the originally filed specification.

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