Auxiliary Tool for Direct Magnetic Element Placement in Electric Motor Rotor
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Solution Overview
Problem
Existing methods for assembling electric motors require permanent magnets to be attached to a support plate before being arranged in the motor's laminations, making the process cumbersome and costly.
Innovation Solution
A device with an auxiliary tool featuring receptacles and detachable holding means allows direct placement of magnetic elements into the rotor unit, eliminating the need for a support plate and enabling controlled, efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent magnets are attached to a support plate before being arranged in the laminations, then the magnets can be securely held during assembly, but the process becomes more complex and time-consuming
Solution Approach 1:
The invention extracts and eliminates the support plate from the assembly process. Instead of attaching magnets to a support plate and then transferring them, the magnets are directly placed into the laminations through recesses in the auxiliary tool. This removes the intermediate support plate component and simplifies the overall assembly process while maintaining secure magnet positioning through the detachable holding means.
Solution Approach 2:
The auxiliary tool is segmented into multiple recesses, each equipped with independent detachable holding means. This allows individual magnets to be separately positioned and secured in specific locations, then transferred to corresponding positions in the laminations. The segmentation enables precise control over each magnet's placement while simplifying the overall process by eliminating the need for a unified support plate.
2Manufacturing precision
If permanent magnets are attached to a support plate before assembly, then the magnets can be positioned accurately, but the production time increases due to intermediate steps
Solution Approach 1:
The detachable holding means in each recess is prepared in advance to securely hold the magnet during the positioning phase. This preliminary securing action allows for accurate magnet placement within the recess, and when the holding means is detached, the magnet is already precisely positioned and ready for transfer to the lamination, eliminating the need for post-positioning adjustments and reducing overall assembly time.
Solution Approach 2:
The invention skips the intermediate step of attaching magnets to a support plate and transferring them as a group. Instead, the detachable holding means allows each magnet to be directly positioned in its final location within the lamination through the recesses, rushing through the assembly process by eliminating unnecessary intermediate transfer steps while maintaining positioning accuracy.
3Productivity
If an auxiliary tool with detachable holding means is used to place magnets directly in the rotor unit, then the assembly process is simplified and accelerated, but the device complexity increases
Solution Approach 1:
The auxiliary tool is designed with multi-functional recesses that can perform multiple operations: holding the magnet securely during positioning, providing alignment guidance through the recess geometry, and facilitating direct transfer to the lamination. The detachable holding means adds a single functional element that enables all these operations within the same recess structure, avoiding the need for separate support plates, alignment tools, and positioning devices, thus achieving multi-functionality without proportionally increasing overall device complexity.
4Ease of manufacture
If permanent magnets are directly placed in the rotor unit without a support plate, then production costs are reduced, but the control over magnet positioning may be compromised
Solution Approach 1:
The detachable holding means acts as an intermediary between the magnet and the lamination during the positioning process. It provides controlled engagement with the magnet, ensuring accurate positioning within the recess, and then can be cleanly detached to leave the magnet in its precise final position. This intermediary mechanism enables direct placement without a support plate while maintaining positioning control through the holding means' engagement features.
Solution Approach 2:
The invention replaces the mechanical support plate system with a more sophisticated but localized detachable holding means mechanism. Instead of relying on a large support plate structure for positioning control, the control is achieved through precisely engineered holding features within each recess that can engage and position the magnet accurately, then release it cleanly. This substitution reduces overall device complexity and cost while maintaining positioning precision through targeted mechanical features.
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 approach simplifies and accelerates the assembly of electric motors by allowing magnetic elements to be positioned directly in the rotor unit without intermediate steps, reducing costs and improving precision.
Implementation Method 1
The auxiliary tool has a detachable holding means (9) for holding the magnetic element (8) arranged in the auxiliary tool (2)
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a device for producing an electric motor, said device comprising an auxiliary tool for arranging magnetic elements in a rotor unit of the electric motor. Said auxiliary tool has a plurality of receiving elements, each receiving element being provided to receive and position a magnetic element. Said receiving elements respectively comprise detachable retaining means for retaining a magnetic element in the receiving element.