Elastic Rotor Insert for Electric Motor Balance Adjustment
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Solution Overview
Problem
Existing electric motor manufacturing processes face challenges in precisely adjusting the balance of the rotor, leading to unstable operation due to vibration caused by an offset center of gravity, requiring a simple and efficient method for balance adjustment.
Innovation Solution
An electric motor design featuring an insert member with a cylindrical body and radial inward protrusions, allowing for elastic deformation to fit within a rotor insert bore, facilitated by a jig with a groove to receive the protrusions, enabling easy insertion and positioning without damaging the motor components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a balance adjustment mechanism is added to the rotor, then the rotor balance precision is improved, but the device complexity increases
Solution Approach 1:
The balance adjustment mechanism is segmented into modular components: an insert member with protrusions, a receptacle with grooves, and adjustable weights. This segmentation allows for simplified manufacturing and assembly while maintaining high balance precision through modular configuration.
Solution Approach 2:
The insert member features elastic deformability that allows it to self-adjust during insertion. The elastic deformation enables the protrusions to automatically engage with the grooves in the receptacle without requiring additional alignment mechanisms or complex installation procedures.
2Ease of manufacture
If an elastic deformable insert member is used, then the ease of manufacture is improved, but the reliability may worsen due to potential deformation issues
Solution Approach 1:
The material parameters of the insert member are specifically selected to achieve optimal elastic deformability. The material is chosen to undergo controlled elastic deformation during insertion while maintaining structural integrity and returning to its original shape, ensuring both ease of manufacture and reliability.
Solution Approach 2:
The design incorporates built-in elastic cushioning that absorbs insertion forces and prevents damage to the rotor or insert member. The elastic deformation acts as a cushioning mechanism that protects against impact damage while facilitating easy insertion.
3Ease of operation
If the insert member is made elastic and deformable, then the ease of operation is improved, but the manufacturing precision may worsen due to deformation variability
Solution Approach 1:
The elastic modulus and geometric parameters of the insert member are precisely controlled during manufacturing to ensure consistent deformation behavior. This allows the insert member to be easily operated while maintaining predictable deformation characteristics that do not compromise manufacturing precision.
Solution Approach 2:
The elastic deformation provides tactile feedback during insertion, allowing operators to sense when the protrusions have engaged with the grooves. This feedback mechanism ensures proper positioning and assembly precision while maintaining ease of operation.
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 solution allows for efficient and cost-effective adjustment of the rotor balance, reducing manufacturing steps and avoiding potential damage, resulting in a reliable and inexpensive electric motor with improved operational stability.
Implementation Method 1
the insert member is elastically deformable such that the outer diameter of the body part becomes smaller than the diameter of the insert bore
Data Source
AI summary
An electric motor includes an insert member situated within an insert bore formed in a rotor in order to adjust a balance of the rotor. The insert member has a body part provided with a cutout portion in a part of its circumference to define a gap extending therebetween. The insert member also has a pair of inner protrusions protruding radially inwardly from the opposite side edges of the gap. The size of the gap is determined such that the gap is not closed when the insert member elastically deforms and as a result, the outer diameter of the insert member becomes smaller than the diameter of the insert bore.