Motor Rotor Assembly Using Vacuum Suction for Bar Alignment
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Solution Overview
Problem
The assembly of conductive bars into slots on a rotor is inefficient due to alignment issues caused by manufacturing tolerance differences between the conductive bars and the assembling plate, leading to reduced assembly efficiency.
Innovation Solution
An assembly apparatus with a rotor fixing module, a conductive bar driving module, and a pumping module that forms a sealed chamber to create suction force, allowing conductive bars to be easily inserted into slots on the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conductive bars are fixed on a movable assembling plate and pushed toward the rotor, then the assembly process can be automated, but alignment difficulty increases due to manufacturing tolerance differences
Solution Approach 1:
A vacuum suction device is introduced as an intermediary between the conductive bars and the rotor. The suction device creates a vacuum field that acts on the conductive bars, pulling them into precise alignment with the rotor slots automatically, thereby resolving the alignment difficulty caused by manufacturing tolerances while maintaining automation
Solution Approach 2:
The traditional mechanical pushing method using a movable assembling plate is replaced with a vacuum field-based system. Instead of mechanically forcing conductive bars into slots (which amplifies alignment errors), the vacuum field gently guides and positions the conductive bars, substituting mechanical force with a field-based approach that tolerates manufacturing variations
2Device complexity
If conventional pushing method is used to insert conductive bars into slots, then simple equipment can be used, but assembly efficiency decreases due to alignment difficulties
Solution Approach 1:
The vacuum suction device serves as a mediating mechanism that enhances assembly efficiency without requiring complex repositioning or manual intervention. It automatically guides conductive bars into slots, resolving alignment issues in real-time during the assembly process, thereby maintaining productivity while keeping the overall system relatively simple
3Manufacturing precision
If manual alignment is performed to compensate for tolerance differences, then assembly precision can be improved, but assembly time increases significantly
Solution Approach 1:
Manual alignment operations are replaced by an automated vacuum field system. The vacuum suction device continuously maintains proper alignment during the insertion process, eliminating the need for time-consuming manual positioning while ensuring consistent precision, thus resolving the time-precision trade-off
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 apparatus simplifies the insertion of conductive bars into slots, enhancing assembly efficiency by utilizing a vacuum force to align and position them accurately.
Implementation Method 1
the pump is able to vacuum the first sealed chamber and create a suction force on the front end of the plurality of conductive bars
Implementation Method 2
create a suction force on the front end of the plurality of conductive bars and draw the plurality of conductive bars into the plurality of slots
Data Source
AI summary
Methods and apparatus are disclosed for assembling a motor rotor. The apparatus includes a rotor fixing module, a conductive bar driving module, a plurality of conductive bars and a pump module. The rotor fixing module supports and holds the rotor. The conductive bar driving module has a plurality of assembling slots. When the pumping module is attached to the conductive bar driving module and each of the conductive bars seals the assembling slots, the pumping module and the assembling slots cooperatively form a sealed chamber, and the pumping module vacuums the sealed chamber to generate a suction force on each of the conductive bars, and the suction force further drives the conductive bars into the assembling slots. The method is for assembling the rotor by utilizing the same procedure mentioned above.