Mold Deformation Inhibiting Surface for Electric Motor Rotor Resin Injection
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Solution Overview
Problem
The existing methods for manufacturing electric motor rotors with permanent-magnet field systems face challenges such as complex manual operations, the need for large-scale equipment, and deformation of the rotor core due to high injection pressure during resin injection, which can affect magnetic flux and operational reliability.
Innovation Solution
A mold with a cavity and a deformation inhibiting surface that comes into contact with the rotor core's outer surface to prevent bulging deformation, allowing accurate and sufficient pouring of resin into gaps between magnet-retaining apertures and permanent magnets, ensuring the rotor core remains undformed and securely fixed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high injection pressure is used to accurately inject resinous material into narrow grooves, then injection accuracy is improved, but rotor core deformation occurs due to bulging of magnetic sheets
Solution Approach 1:
The mold cavity is designed with a deformation inhibiting surface that comes into contact with the outer circumferential surface of the rotor core to apply a counteracting force against the bulging deformation caused by high injection pressure, thereby preventing rotor core deformation while maintaining accurate resin injection
2Manufacturing precision
If high injection pressure is applied to fill narrow grooves, then resin injection completeness is improved, but magnetic flux is affected and operational reliability deteriorates
Solution Approach 1:
The deformation inhibiting surface is positioned to contact the rotor core's outer circumferential surface at a location corresponding to the groove region, preventing bulging deformation before it occurs during high-pressure resin injection, thereby ensuring complete resin filling without affecting magnetic flux or operational reliability
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
The solution enables the production of electric motor rotors with excellent operational reliability by preventing deformation and ensuring accurate resin injection, thereby enhancing the fixing strength and reproducibility of the rotor core with permanent magnets.
Implementation Method 1
the resinous material is injected into the gaps between the respective magnet-retaining apertures and the respective permanent magnets
Data Source
AI summary
A mold used in a manufacturing process of a rotor of an electric motor, the rotor including a rotor core with a plurality of magnet-retaining apertures and a plurality of permanent magnets individually retained in the magnet-retaining apertures of the rotor core, for pouring a resinous material into gaps defined between the magnet-retaining apertures and the permanent magnets. The mold includes a cavity for accommodating the rotor core at a predetermined position, with the rotor core receiving the permanent magnets individually in the magnet-retaining apertures; and a deformation inhibiting surface provided in the cavity and coming into at least local contact with an outer circumferential surface of the rotor core, during a period when the resinous material is poured into the gaps, to inhibit the bulging deformation of the outer circumferential surface.