Permanent Magnet Assembly Alignment for Dynamo-Electric Machines
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Solution Overview
Problem
The existing method of cleaving permanent magnets for rotating electrical machines results in shifts between magnet pieces, restricting magnet dimensions and motor performance due to inadequate alignment and integration techniques.
Innovation Solution
A manufacturing device and method that aligns and joins fractured magnet pieces using an adhesive, employing first, second, and third pressing means to correct shifts in the width, thickness, and longitudinal directions, ensuring precise alignment and integration without positional shifts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the permanent magnet is cleft in the container and the magnet pieces are integrated by the resin, then the eddy current is reduced and heat generation is suppressed, but shifts are generated between the magnet pieces in thickness direction, width direction, and length direction, restricting magnet dimension and motor performance
Solution Approach 1:
The magnet pieces are preliminarily aligned in the integrating jig before resin injection, ensuring precise positioning in thickness direction, width direction, and length direction. This preliminary alignment action prevents shifts during the integration process while maintaining the eddy current reduction benefits of the cleaved structure
Solution Approach 2:
The integrating jig acts as an intermediary device that holds and aligns the magnet pieces precisely during the resin injection process. The jig ensures that magnet pieces are positioned correctly before the resin sets, preventing dimensional shifts while allowing the resin to infiltrate and bond the pieces together
2Strength
If the magnet pieces are integrated by resin infiltration in the container, then the magnet pieces are bonded together, but shifts occur in thickness direction, width direction, and length direction due to inadequate alignment control
Solution Approach 1:
The magnet pieces are preliminarily aligned and fixed in the integrating jig before resin injection. This preliminary positioning ensures that the pieces maintain accurate dimensional relationships during bonding, preventing shifts in thickness, width, and length directions while ensuring proper bonding strength
Solution Approach 2:
The integrating jig serves as an intermediary alignment device that maintains precise positioning of magnet pieces during the resin bonding process. The jig's structure ensures that pieces are held in correct alignment while the resin infiltrates and bonds them, preserving both bonding strength and dimensional accuracy
3Loss of energy
If the permanent magnet is cleaved into magnet pieces, then the surface area is reduced and eddy current is suppressed, but the magnet dimension is restricted due to generation of shifts between pieces
Solution Approach 1:
The magnet pieces are preliminarily aligned in the integrating jig before resin injection, ensuring precise positioning that prevents dimensional shifts. This allows the magnet to be cleaved into pieces for eddy current reduction while maintaining accurate overall magnet dimensions through the alignment process
Solution Approach 2:
The integrating jig acts as an intermediary device that enables the magnet to be both cleaved into pieces (reducing eddy current) and maintain accurate dimensions. The jig's alignment features ensure that cleaved pieces are positioned precisely during integration, allowing larger magnet dimensions without dimensional inaccuracies
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 approach enhances the yield of permanent magnets by preventing defective assembly, allowing for larger magnet dimensions, improved motor output, and reduced friction during alignment, while maintaining cost-effectiveness and ensuring proper adhesion force distribution.
Implementation Method 1
a plurality of magnet pieces, each formed by fracture and split along a notch groove, are aligned and joined to each other by interposing an adhesive between fractured surfaces
Implementation Method 2
reduced friction during alignment
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
This invention is a manufacturing device for a permanent magnet disposed in a rotating electrical machine, in which a plurality of magnet pieces, each formed by being fractured and split along a notch groove, are aligned and joined to each other with an adhesive interposed between fractured surfaces. First pressing means for aligning the plurality of fractured and split magnet pieces with the fractured surfaces opposed to each other in a thickness direction by pressing from the thickness direction of the permanent magnet, second pressing means for aligning the plurality of magnet pieces in a width direction by pressing from a width direction of the permanent magnet are provided. Moreover, third pressing means for joining the opposing fractured surfaces of the magnet piece with the interposed adhesive by pressing the plurality of magnet pieces from a longitudinal direction of the permanent magnet.