Guide Member Resin Flow for Laminated Core Adaptability
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Solution Overview
Problem
Existing methods for manufacturing laminated cores require frequent changes to molding dies and dummy plates when the positions or numbers of magnet insertion holes change, leading to increased manufacturing costs and production downtime.
Innovation Solution
A method involving a guide member with groove-type resin passages and gates is used between the molding die and laminated core body, allowing resin to be filled into magnet insertion holes without altering the molding die, using a guide member made of flat plates with resin passages and gates that facilitate easy resin removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If molding die shape is changed according to laminated core body type, then magnet insertion hole positions and numbers can be adapted, but manufacturing cost increases and production time increases
Solution Approach 1:
The invention divides the molding system into two independent parts: a standard molding die and a replaceable guide member. The guide member contains the resin passages and gates that are specific to each laminated core body type, while the molding die remains unchanged. This segmentation allows quick replacement of only the guide member (with various configurations for different magnet insertion hole positions and numbers) instead of replacing the entire molding die, thereby reducing production lead time while maintaining adaptability to different core body types
Solution Approach 2:
The guide member acts as an intermediary component between the molding die and the laminated core body. It mediates the resin flow from the molding die to the magnet insertion holes, allowing the system to adapt to different core body configurations without modifying the molding die itself. The guide member can be easily replaced with different types corresponding to different magnet insertion hole arrangements, enabling flexible production while minimizing downtime
2Adaptability or versatility
If molding die shape is changed according to laminated core body type, then magnet insertion hole positions and numbers can be adapted, but manufacturing cost increases
Solution Approach 1:
The invention segments the molding system into a standard molding die and replaceable guide members. Only the guide members need to be manufactured in different types to accommodate various magnet insertion hole configurations, while the expensive molding die remains standardized. This significantly reduces manufacturing costs compared to creating multiple customized molding dies
Solution Approach 2:
The guide member is designed as a relatively simple, replaceable component that can be manufactured at lower cost compared to a full molding die. When production requirements change, instead of investing in new expensive molding dies, the system uses inexpensive guide members that can be quickly replaced, reducing overall manufacturing costs
3Productivity
If molding resin is injected directly into magnet insertion holes, then magnet pieces can be fixed, but resin remains on product surface requiring removal process
Solution Approach 1:
The invention extracts the resin passage structure from the molding die and places it in the replaceable guide member. The guide member is designed with resin passages and gates such that when removed, any residual molding resin is taken out with the guide member itself, leaving the laminated core body surface clean. This eliminates the need for additional resin removal processes while maintaining efficient resin injection
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
Enables continuous production without stopping the line, reduces lead time and manufacturing costs by allowing guide member changes only, and prevents resin from remaining on the product surface, making it easier to remove residual resin.
Implementation Method 1
a guide member including: a) groove-type resin passages provided from the resin reservoir portions to the magnet insertion holes; and b) gates on downstream sides of the resin passages, the gates connected to the magnet insertion holes
Data Source
AI summary
In a method of manufacturing a laminated core, a laminated core body 14 including magnet insertion holes 12 and 13 with magnet pieces 15 inserted therein is placed between a molding (upper) die 10 and a retaining (lower) die 11, and a molding resin 19 is filled from resin reservoir portions (pots) 16 to fix the pieces 15 in the holes 12 and 13. Between the die 10 and the body 14, a guide member 18 is placed, which includes resin passages 31 provided from the portions 16 to the holes 12 and 13 and gates 30 connecting to the holes 12 and 13 on downstream sides of the passages 31. The method can reduce lead time of a production line without replacing the molding dies for different laminated rotor cores and thus without preparing different types of molding dies.