Magnet Insertion Assembly with Chamfered Front Member
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Solution Overview
Problem
The existing methods for inserting magnet pieces into a rotor core of electric motors face challenges such as high manufacturing costs and performance deterioration due to chamfering, as well as issues with magnet pieces getting stuck in the insertion hole when corners are not chamfered.
Innovation Solution
A magnet insertion method involving an assembly of laminated magnet pieces, where the front piece has a chamfered surface acting as a guide, and the subsequent pieces without chamfers are aligned to be hidden inside the projection of the front piece, allowing for accurate alignment and insertion without the need for extensive chamfering of all pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If corners of magnet pieces are subjected to chamfering to prevent them from getting stuck, then ease of insertion is improved, but manufacturing cost increases greatly and magnet performance deteriorates due to reduction in magnet volume
Solution Approach 1:
The invention applies chamfering only to specific local areas (the leading corners of magnet pieces that contact the insertion hole) rather than all corners, thereby achieving the necessary guidance for insertion while minimizing material removal and cost
Solution Approach 2:
The magnet pieces are divided into multiple smaller pieces rather than using a single large magnet, which allows selective chamfering of only the leading edges of each piece, reducing overall manufacturing cost while maintaining insertion capability
2Ease of operation
If corners of magnet pieces are subjected to chamfering to prevent them from getting stuck, then ease of insertion is improved, but magnet performance deteriorates due to reduction in magnet volume
Solution Approach 1:
Chamfering is applied selectively only to the leading corners of magnet pieces that make contact with the insertion hole during insertion, preserving the volume and magnetic properties of the main body of each magnet piece
Solution Approach 2:
By dividing the magnet into multiple smaller pieces, the invention reduces the overall chamfering volume required while maintaining adequate guidance, thereby preserving more magnetic material and performance
3Ease of manufacture
If magnet pieces are separately inserted into the magnet insertion hole to reduce manufacturing costs, then ease of manufacture is improved, but the magnet pieces get easily stuck in the middle of the magnet insertion hole and do not reach the bottom
Solution Approach 1:
The invention divides the magnet into multiple smaller pieces that are inserted separately, reducing manufacturing costs while implementing selective chamfering to ensure smooth insertion without getting stuck
Solution Approach 2:
Selective chamfering of the leading corners of each magnet piece provides the necessary guidance for separate insertion, preventing the pieces from getting stuck in the middle of the insertion hole while maintaining cost effectiveness
Data Source
AI summary
A magnet insertion method into a rotor core is to insert an assembly into a magnet insertion hole provided in the rotor core of an electric motor, the assembly being formed by laminating a plurality of members, including at least a plurality of magnet pieces, in a line. According to this magnet insertion method, the assembly is formed by arranging a front member, having a surface surrounded by a chamfered ridge line, to cause the surface to be a front side end surface upon insertion, by laminating, on its rear side in an insertion direction, other members, without having the chamfered ridge line, in a line along the insertion direction to cause the other members to be hidden inside a projection of the front member when being projected from an insertion hole side, and by temporarily holding the front member and the other members.