Flexible Molding Process for Magnetic Pole Protective Layer
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Solution Overview
Problem
The existing adhesive injection process for magnetic pole protective layers in electric motors often results in holes and bubbles, which affect the performance and service life of the protective layer, particularly in the lower one-third region of the magnetic yoke, due to incomplete impregnation and gas adsorption.
Innovation Solution
A flexible molding process and system that includes assembling magnet steels on a magnetic yoke, laying a reinforcing material and vacuum bag, vacuumizing the system, and performing heating and ultrasonic wave emission during the impregnation process to reduce bubbles and enhance infiltration, followed by a curing process to form a robust protective layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum impregnation is performed without heating and ultrasonic treatment, then the process is simple and quick, but holes and bubbles remain in the protective layer reducing its quality
Solution Approach 1:
The patent combines heating device, ultrasonic wave emitting device, and vacuum pump into an integrated impregnation system. The heating device and ultrasonic device work simultaneously with the vacuum pump during the impregnation process, merging multiple functions into one coordinated system that eliminates bubbles and holes while maintaining operational simplicity
Solution Approach 2:
The heating device pre-heats the resin before and during impregnation to reduce its viscosity and improve flow characteristics. The ultrasonic device is activated during impregnation to pre-remove bubbles from the resin and reinforcing material. These preliminary actions ensure complete impregnation without defects before the curing process begins
2Productivity
If traditional adhesive injection is used, then the process is fast and simple, but incomplete impregnation occurs leaving holes in the lower one-third region
Solution Approach 1:
The vacuum pump operates in periodic cycles during impregnation, alternating between vacuum suction and atmospheric pressure phases. This periodic action creates pressure differentials that drive resin into all regions including the difficult-to-reach lower one-third area, ensuring complete impregnation without extending total process time significantly
Solution Approach 2:
The patent changes physical parameters during impregnation by controlling temperature through the heating device and pressure through the vacuum pump. The resin temperature is maintained at optimal levels to reduce viscosity and enhance flow, while pressure parameters are dynamically adjusted to ensure complete infiltration into all regions of the reinforcing material
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
The proposed process significantly reduces the number of holes in the protective layer by improving liquid impregnation and infiltration, enhancing the bonding and curing of the resin, thereby increasing the strength and durability of the magnetic pole component.
Implementation Method 1
The sealed system is vacuumized by means of a vacuum pump 18 to compact the reinforcing material 142, to generate a drive pressure gradient required for impregnating liquid
Implementation Method 2
heating the sealed system and/or emitting ultrasonic waves to the sealed system while performing the impregnation process
Implementation Method 3
heating the sealed system and/or emitting ultrasonic waves to the sealed system while performing the impregnation process
Implementation Method 4
performing a curing process after the impregnation process, wherein the impregnation liquid and the reinforcing material are cured to form a protective layer
Data Source
AI summary
A flexible molding process and system for a magnetic pole protective layer. The molding process is as follows: assembling magnet steels at respective positions on a side wall surface of a magnetic yoke, laying a reinforcing material and a vacuum bag in the listed sequence on the magnet steel and the side wall surface of the magnetic yoke, wherein the vacuum bag, the magnet steels and the side wall surface of the magnetic yoke form a sealed system; performing an impregnation process, including vacuumizing the sealed system to allow the impregnation liquid to be injected into the sealed system, to achieve infiltration and impregnation; heating the sealed system and/or emitting ultrasonic waves to the sealed system while performing the impregnation process; and performing a curing process after the impregnation process, wherein the impregnation liquid and the reinforcing material are cured to form a protective layer.