Core Unit Manufacturing Apparatus with Separate Resin and Core Transfer Units
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Solution Overview
Problem
The existing methods for manufacturing core units in rotating electric machines, such as stators and rotors, face inefficiencies due to complex mechanisms and the need for separate carrying-in mechanisms, which can lead to decreased resin quality and increased manufacturing time, as the resin material and core body are typically carried into the molding device from the same side, causing overlap in movement paths and potential solidification issues.
Innovation Solution
A core unit manufacturing apparatus where the resin material and core body are carried into the molding device from different directions, utilizing separate resin and core transfer units to simplify movement paths and avoid interference, allowing for simultaneous setup and injection of resin into the core body without time intervals, ensuring proper resin filling before solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the resin material and core body are carried into the molding device from the same side, then the structure of the molding device can be simplified, but the carrying-in mechanisms become complicated and manufacturing efficiency decreases
Solution Approach 1:
The invention divides the carrying-in operation into two separate segments: one mechanism carries the core body while another mechanism carries the resin material. This segmentation allows both items to be carried in simultaneously from different sides without interference, simplifying each individual mechanism while maintaining high manufacturing efficiency.
2Ease of operation
If the resin material is carried in first and then the core body, then the carrying-in mechanism can be operated sequentially, but the resin solidifies before injection is completed
Solution Approach 1:
The invention performs preliminary actions by having both the core body and resin material carried into position before the injection process begins. The resin material is prepared and positioned in advance, and the core body is positioned simultaneously, ensuring that injection can proceed immediately without delay that would cause resin solidification.
3Reliability
If separate mechanisms are required to retract carrying-in mechanisms, then interference between mechanisms is avoided, but the mechanisms become more complicated and manufacturing time increases
Solution Approach 1:
The invention resolves mechanism interference by transitioning to another dimension - using spatial separation with multiple carrying-in mechanisms positioned at different locations (different sides) of the molding device. This eliminates the need for retraction movements and complex coordination, as each mechanism operates independently in its own spatial zone.
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 enhances manufacturing efficiency, reduces complexity and costs, and improves resin quality by allowing for continuous and quick filling of resin into the core unit, ensuring the resin is injected before it solidifies, thus maintaining its quality.
Implementation Method 1
a heating unit that heats the resin material; a molding step of injecting the heated and molten resin into the laminated core
Implementation Method 2
a molding device that injects the heated and molten resin into the laminated core
Data Source
AI summary
There are provided a core unit manufacturing apparatus and a core unit manufacturing method including: a molding device that fills a resin into a space portion in a core body; a resin transfer unit that transfers a resin material to the molding device to supply the resin material thereto; and a core transfer unit that carries the core body in and out of a part between a pair of dies of the molding device. The resin transfer unit and the core transfer unit are arranged such that: the resin transfer unit supplies the resin to the molding device from one side position of side surfaces of the molding device; and the core transfer unit carries the core body in and out of the molding device from the other side position of the side surfaces of the molding device, the other side position being different from one side position.