Magnet Wheel Cold Forging Groove Formation

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Solution Overview

Problem

The conventional production of magnet wheels for alternators with permanent interpolar magnets involves time-consuming and costly machining operations to create grooves and magnet lips, which are not efficiently addressed by existing forging methods.

Innovation Solution

A method combining hot and cold forging steps to pre-form magnet receptacle grooves and lips on magnet wheels, using a cold forging die with successive axial blows to form the grooves and lips, followed by cutting surplus material, reducing production time and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If machining operations are used to produce grooves and magnet lips after forging, then manufacturing precision is improved, but productivity is reduced and manufacturing cost increases

Engineering Contradiction:

Improvegroove and magnet lip precisionVSAvoidproduction duration

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines the formation of grooves and magnet lips with the forging operation itself, merging two previously separate processes (forging and machining) into one integrated cold forging step. This eliminates the need for subsequent machining operations while maintaining the required precision for magnet retention.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The grooves and magnet lips are pre-formed during the cold forging step before the hot forging and machining operations. By performing the groove and lip formation in advance as part of the cold forging process, the patent eliminates the need for time-consuming post-forging machining operations.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If machining operations are used to produce grooves and magnet lips after forging, then manufacturing precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvegroove and magnet lip precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent merges the groove and magnet lip formation with the cold forging operation, eliminating the need for separate machining operations. This integration reduces manufacturing complexity and cost while maintaining the precision required for proper magnet retention.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If hot forging only is used to produce magnet wheel, then productivity is improved, but manufacturing precision of grooves and lips is insufficient

Engineering Contradiction:

Improveproduction efficiencyVSAvoidgroove and magnet lip precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent segments the forging process into two distinct stages: cold forging for precise groove and magnet lip formation, followed by hot forging for final shaping. This segmentation allows each stage to optimize for its specific function, with cold forging providing precision and hot forging providing productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cold forging step performs the preliminary action of forming grooves and magnet lips with high precision before the hot forging operation. This preliminary formation ensures that the critical features are created with the necessary accuracy before the final high-productivity hot forging step.

Inventive Principle:

Principle #10Preliminary action

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 significantly reduces production time and cost by integrating groove and lip formation into the forging process, enhancing mechanical resistance to centrifugal forces and improving the efficiency of magnet wheel production.

Implementation Method 1

application by means of cold die stamping of a first blow on the basic magnet wheel, in the axial direction of the latter, giving rise to a first upsetting of material onto inner parts of the polar teeth

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

The invention relates to a method for forging a magnet wheel... comprising a hot forging step and a cold forging step which intervenes after the hot forging step

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS10601289B2Method for forging magnet wheel for motor vehicle alternator using cold forging die, and magnet wheel obtained by this method

Publication Date: 2020.03.24 VALEO EQUIP ELECTRIC MOTEUR

AI summary

The method according to the invention involves a hot-forging step and a cold-forging step that occurs after the hot-forging step. A polar wheel (10, 11) incorporating a plurality of finite chamfers (102) formed on exterior parts of the polar teeth (10g, 11g) is produced during the hot-forging step. According to the invention, the cold-forging step involves substeps of placing the polar wheel in a die, cold die-stamping the polar wheel with a first and a second blow in the axial direction of the polar wheel, upsetting material onto interior parts of the polar teeth (10g, 11g) so as to form magnet-housing grooves (100) and magnet lips (101).