Dividable Rotor Core Assembly for Electric Motors
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Solution Overview
Problem
The production of electric motors with dividable cores is hindered by increased production time due to uneven gaps and misalignment between components, leading to inefficient motor operation and mechanical instability under centrifugal forces.
Innovation Solution
A rotor design featuring a generally annular supporting member with shaft portions and divided cores that are connected by rotating connecting portions around the shafts, allowing for precise fitting and assembly without gaps, along with a cylindrical member for interference fit to ensure smooth operation and mechanical reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a dividable core is used to effectively utilize magnetic steel sheets, then material utilization is improved, but production time increases due to increased number of components and assembly complexity
Solution Approach 1:
The rotor core is divided into multiple divided cores that can be separately manufactured and then assembled together. This segmentation allows for more flexible utilization of magnetic steel sheets while reducing the complexity of each individual component, thereby improving both material utilization and assembly efficiency
Solution Approach 2:
The divided cores are pre-assembled onto the supporting member before final rotor assembly. This preliminary positioning ensures proper alignment and reduces adjustment time during final assembly, thereby reducing overall production time while maintaining the benefits of divided core construction
2Manufacturing precision
If components are fitted together to eliminate gaps, then manufacturing precision is improved, but workability deteriorates and production time increases
Solution Approach 1:
Shaft portions are introduced as intermediary elements between the divided cores and the supporting member. These shaft portions serve as precise positioning features that automatically ensure uniform gaps between adjacent divided cores when assembled, eliminating the need for complex adjustment procedures while maintaining high manufacturing precision
Solution Approach 2:
The connecting portions of the divided cores are designed to automatically align and connect to neighboring divided cores through a rotating motion about the shaft portions. This self-aligning mechanism ensures uniform gaps without requiring manual adjustment, thereby maintaining manufacturing precision while improving assembly workability
3Reliability
If a dividable core is used for rapidly rotating rotor, then mechanical reinforcement is needed to resist centrifugal force, but device complexity increases due to additional reinforcing members
Solution Approach 1:
The shaft portions serve dual functions: they act as connecting elements between divided cores and simultaneously provide mechanical reinforcement to resist centrifugal forces during high-speed rotation. This merging of functions eliminates the need for separate reinforcing members, thereby improving reliability without increasing device complexity
Solution Approach 2:
The connecting portions between divided cores are designed to provide both positional alignment and structural reinforcement. These multi-functional connecting portions eliminate the need for additional dedicated reinforcing members, maintaining simplicity while ensuring the rotor can withstand centrifugal forces during rapid rotation
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 design reduces production time, ensures even gaps, enhances assembly workability, and provides mechanical stability by allowing precise positioning and connection of divided cores, resulting in a smoothly operating electric motor with improved resistance to centrifugal forces.
Implementation Method 1
a cylindrical member fitted to an inner portion of the annular core
Data Source
AI summary
A rotor having a dividable core for an electric motor, and a production method thereof. A rotor has a generally annular supporting member; a plurality of shaft portions positioned on the supporting member in a circumferential direction at regular intervals, the shaft portions extending generally parallel to a rotation axis of the rotor; and a plurality of divided cores each having a hole portion which is fitted to each shaft portion. By annularly connecting the divided cores, a generally annular dividable core for the rotor is formed. Each divided core has connecting portions at both circumferential ends thereof, and each connecting portion is configured to be connected to a connecting portion of a neighboring divided core while the divided core is fitted to the shaft portion.