Permanent Magnet Rotor Assembly Without Pipe Scratching
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Solution Overview
Problem
The magnet reinforcement pipe in existing permanent magnet rotating electric machines can become scratched during the press-fitting process, leading to a reduction in its strength and potential failure under centrifugal force.
Innovation Solution
A rotor manufacturing method that involves filling resin between the rotor shaft and the permanent magnet, using charging pressure to expand the magnet reinforcement pipe without scratching it, thereby imparting compression stress to the permanent magnet for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If precise diameter matching is required for press-fitting, then fixing strength can be achieved, but manufacturing complexity and precision requirements increase
Solution Approach 1:
The patent changes the fixation mechanism from relying on precise dimensional parameters (diameter matching for press-fitting) to relying on the chemical and physical properties of resin (liquid state for filling, then hardening to solid state). This parameter change allows for greater tolerance in diameter dimensions while still achieving sufficient fixing strength, as the resin can accommodate variations in size and provide consistent bonding.
Solution Approach 2:
The resin acts as a compensating intermediary that absorbs dimensional variations and tolerances. Instead of requiring precise diameter matching between components, the liquid resin fills any gaps or variations in size, and upon hardening, provides uniform fixation. This eliminates the need for high-precision machining and diameter matching while maintaining fixing strength.
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 method prevents a drop in strength due to scratching of the magnet reinforcement pipe, ensuring the rotor can withstand high-speed rotation and eliminating the need for precise diameter matching and high-precision processing, thus enhancing the rotor's quality and performance.
Implementation Method 1
filling the resin in liquid form between the rotor shaft and the permanent magnet, breaking the permanent magnet using charging pressure of the resin, and expanding a diameter of the magnet reinforcement pipe
Implementation Method 2
compression stress can be imparted to the permanent magnet between the magnet reinforcement pipe and the resin without scratching the magnet reinforcement pipe, enabling sufficient fixing strength to be obtained for the permanent magnet
Data Source
AI summary
In the present rotor manufacturing method, when manufacturing a rotor including a rotor shaft, a permanent magnet held on the outer circumference of the rotor shaft via a resin, and a magnet reinforcing pipe formed in a cylindrical shape and covering the permanent magnet from the outer circumferential side, the liquid resin is filled between the rotor shaft and the permanent magnet, and the permanent magnet is broken and the magnet reinforcing pipe is expanded in diameter by the filling pressure of the resin.