Magnetic Modulator Assembly With Precision Peripheral Machining
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Solution Overview
Problem
The existing magnetic modulation gears face challenges in achieving sufficient shape accuracy of the magnetic pole piece member's peripheral surfaces, leading to inadequate output performance due to insufficient assembly precision.
Innovation Solution
A method involving axial lamination of electromagnetic steel sheets with magnetic pole pieces and connection portions, followed by resin molding and precise removal processing of the inner and outer peripheral surfaces to achieve circularity and coaxiality of 10 μm or less, enhancing the shape accuracy and integration with the shaft member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If magnetic pole pieces and shaft member are simply assembled, then device complexity is reduced, but shape accuracy and assembly precision deteriorate
Solution Approach 1:
The magnetic pole pieces are preliminarily fixed to the shaft member using resin molding before final assembly. This preliminary action ensures that the peripheral surfaces maintain their required shape accuracy and that the components remain in precise relative positions throughout the manufacturing process, preventing assembly errors while managing complexity through staged fabrication.
2Manufacturing precision
If resin molding is used to integrate magnetic pole piece member and shaft member, then assembly precision is improved, but manufacturing time increases
Solution Approach 1:
The resin molding process merges the magnetic pole piece member and shaft member into a single integrated assembly in one manufacturing step. This combining approach achieves high assembly precision by permanently bonding the components in their correct relative positions, eliminating the need for separate assembly operations and subsequent adjustments, thereby reducing total manufacturing time despite the added molding step.
3Reliability
If removal processing is performed on peripheral surfaces, then output performance is improved, but manufacturing complexity increases
Solution Approach 1:
Removal processing is applied locally only to the peripheral surfaces of the magnetic pole piece member that require high precision for optimal output performance. This selective local quality approach ensures that critical surfaces achieve the necessary accuracy while avoiding unnecessary processing of other areas, thereby improving reliability without proportionally increasing manufacturing complexity across the entire component.
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 improves the centering accuracy and reduces torque ripple and losses during power conversion, resulting in superior output performance and increased torque capacity.
Implementation Method 1
a magnetic pole piece member made by axially laminating electromagnetic steel sheets each having a plurality of magnetic pole pieces arranged in a circumferential direction
Implementation Method 2
a second process of performing resin molding to integrate the magnetic pole piece member and the shaft member with resin
Data Source
AI summary
A method for manufacturing a magnetic modulator that includes a magnetic pole piece member having a plurality of magnetic pole pieces arranged in a circumferential direction and a connection portion connecting adjacent magnetic pole pieces to each other in the circumferential direction, and a shaft member, the method including: a first process of manufacturing the magnetic pole piece member by axially laminating electromagnetic steel sheets each having the plurality of magnetic pole pieces and the connection portions; a second process of performing resin molding to integrate the magnetic pole piece member and the shaft member with resin; and a third process of performing removal processing on at least one of an inner peripheral surface and an outer peripheral surface of the magnetic pole piece member.