Field Pole Magnet Manufacturing with Segmented Pushing Parts
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Solution Overview
Problem
The manufacturing of field-pole magnets using adhesive or resin bonding faces issues with unbalanced pushing forces due to contamination and burrs, leading to deviations and malformations in the magnet pieces.
Innovation Solution
A manufacturing device that applies pushing forces from multiple directions using individually biased pushing parts and spacers to ensure even force distribution, avoiding contamination and burr-induced imbalances, with a support structure to maintain precise alignment and dimension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pushing member is used to push multiple magnet pieces, then the device structure is simple, but contamination or burrs cause unbalanced pushing forces leading to positioning deviations
Solution Approach 1:
The single pushing member is divided into multiple independent pushing parts, each responsible for pushing one magnet piece. This segmentation ensures that contamination or burrs affecting one pushing part do not impact the others, maintaining balanced pushing forces and positioning accuracy across all magnet pieces.
Solution Approach 2:
Each pushing part is equipped with an individual spring mechanism that provides localized pushing force. This allows each pushing part to independently compensate for contamination or burrs at its specific contact point, ensuring uniform pushing forces are applied to each magnet piece despite local variations in surface conditions.
2Manufacturing precision
If individually biased pushing parts are used to ensure balanced pushing forces, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
Multiple pushing parts with individual spring mechanisms are merged into a single integrated pushing member structure. This combination achieves the benefit of individually biased pushing parts for balanced force distribution while maintaining structural compactness and avoiding excessive device complexity.
Solution Approach 2:
The pushing member is designed with multiple pushing parts that can independently function for different magnet pieces. Each pushing part serves multiple purposes: applying pushing force, compensating for contamination, and ensuring uniform contact. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
3Force
If spring mechanisms are added to each pushing part for individual force control, then pushing force balance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The spring mechanisms allow the pushing force parameter to be automatically adjusted for each pushing part based on local conditions such as contamination or burrs. This parameter change capability ensures balanced pushing forces without requiring complex control systems, as the spring characteristics (force constant, pre-compression) can be standardized to achieve force balance across all pushing parts.
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 ensures balanced pushing forces, enhancing the precision and accuracy of field-pole magnet manufacturing by preventing deviations and malformations, and allowing for less stringent control over pushing part dimensions and positions.
Implementation Method 1
a pushing part (5) which pushes the magnet piece (1) with a spring (15)
Implementation Method 2
bonding a plurality of magnet pieces with an adhesive or a resin
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A one-piece field-pole magnet is manufactured by filling a gap formed between magnetic pieces placed on a plane with an adhesive or resin. During the process, a pushing member applies a pushing force onto each of the magnet pieces in a thickness direction thereof. The pushing member comprises pushing parts each of which pushes each of the magnet pieces, thereby equalizing the pushing forces applied to the respective magnet pieces.