IPM Rotor Multi-Point Injection for Complete Gap Filling
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Solution Overview
Problem
Conventional IPM rotors face challenges in achieving optimal NV characteristics due to incomplete filling of resin in the gap between the rotor core and permanent magnets, leading to potential degradation in noise and vibration performance.
Innovation Solution
An apparatus and method for manufacturing IPM rotors that provide multiple inlets for injecting a filler into the gap between the magnet and the core body, ensuring thorough filling of the gap, including inner and outer circumferential portions and corner areas, to enhance coupling rigidity and hold the magnet securely against centrifugal forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin is injected into the gap between the rotor core and permanent magnet, then the coupling rigidity is improved, but the resin has low fluidity causing incomplete filling of the gap
Solution Approach 1:
The injection system is segmented into multiple inlets distributed around the slot, allowing resin to be injected from multiple locations simultaneously. This segmentation overcomes the low fluidity limitation by creating multiple flow paths that collectively fill the entire gap, ensuring complete filling while achieving the required coupling rigidity.
2Manufacturing precision
If multiple inlets are provided for injecting filler, then the gap filling is improved, but the device complexity increases
Solution Approach 1:
The multiple inlets are designed as part of a universal injection system that serves the entire slot structure. Rather than complex individual injection mechanisms for each inlet, the system uses a simplified multi-point injection approach where all inlets follow the same design pattern, reducing overall complexity while achieving complete gap filling.
Data Source
AI summary
An injection apparatus includes a gate for injecting a filler to a gap between an inner wall of a slot and a permanent magnet. A plurality of gates are provided for one slot. An IPM rotor with improved NV characteristics, and method and apparatus for manufacturing such an IPM rotor can be provided by such a structure.