Diecast Rotor Can with Integrated Backing Ring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The fabrication of heavily loaded rotor motors for large fans is time-consuming and costly, requiring precise machining and balancing, which can be labor-intensive and inefficient.
Innovation Solution
The motor design incorporates a diecast rotor can with a non-machined sidewall and a securely interengaged backing ring, eliminating the need for fasteners or adhesives by integrating the backing ring during the diecasting process, thus simplifying the assembly and balancing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining and assembly methods are used for rotor fabrication, then structural precision and component securing are achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The backing ring is integrated directly into the rotor can during the diecasting process, combining two separate manufacturing operations (casting the can and machining/assembly of the backing ring) into a single integrated process. This eliminates intermediate machining and assembly steps while maintaining the required structural precision through the diecasting tooling design.
Solution Approach 2:
The backing ring is formed as an integral part of the rotor can during the initial diecasting process, performing the function of the backing ring before any subsequent assembly operations would be needed. This preliminary formation eliminates the need for separate machining and assembly operations that would otherwise be required to secure the backing ring to the rotor can.
2Strength
If multiple separate components (can, backing ring, magnets) are assembled with fasteners and adhesives, then structural integrity is achieved, but assembly complexity and time increase
Solution Approach 1:
The backing ring and rotor can are merged into a single integrated component through the diecasting process, eliminating the need for separate fasteners and adhesives to secure them together. The integrated structure maintains rotor structural integrity while removing the complexity of multiple assembly steps and fastening mechanisms.
Solution Approach 2:
The diecasting process itself creates the structural connection between what would otherwise be separate components (rotor can and backing ring), making the manufacturing process self-sufficient for creating secure connections without requiring additional fastening operations or materials like adhesives.
3Stability of the object's composition
If precise press-fit connections and fasteners are used to secure backing ring, then relative shifting is restricted, but manufacturing time and cost increase
Solution Approach 1:
The backing ring and rotor can are formed as a single integrated component during diecasting, eliminating the need for press-fit connections or fasteners to prevent relative shifting. The components are positioned stably relative to each other by being part of the same monolithic structure created during the casting process.
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 reduces manufacturing time and costs by eliminating the need for secondary machining and balancing operations, while maintaining structural integrity and rotational symmetry, enhancing motor performance and efficiency.
Implementation Method 1
The rotor can is diecast in an overlying relationship with at least part of the backing ring
Data Source
AI summary
An electric fan includes a plurality of blades and an electric motor for rotating the blades. The electric motor includes a stator and a rotor rotatable relative to the stator about an axis. The rotor includes a backing ring and a diecast rotor can. The can includes a non-machined sidewall that is diecast integrally as part of the rotor can. The sidewall extends about the axis. The rotor can is diecast in an overlying relationship with at least part of the backing ring, with the sidewall and backing ring being securely interengaged so as to restrict relative shifting therebetween.