Resin Sealing Device for Magnet Embedded Core
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Solution Overview
Problem
The existing resin sealing process for magnet embedded cores in rotating electric machinery often results in excessive pressurizing forces, leading to deformation of the laminated iron core, which impairs the planarity of end surfaces, varies stacking height, and causes resin peeling or cracking, making it difficult to achieve high-quality cores with geometric and dimensional precision.
Innovation Solution
A resin sealing device with a die clamping system using multiple electric motors and feedback control mechanisms to apply a controlled pressurizing force, ensuring precise movement and pressure distribution, thereby minimizing resin leakage and maintaining core precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large pressurizing force is applied to prevent resin leakage, then resin sealing reliability is improved, but the laminated iron core deforms and planarity is impaired
Solution Approach 1:
The pressurizing force is segmented and applied locally at multiple magnet insertion hole positions rather than uniformly across the entire iron core. This localized pressurization prevents resin leakage at critical points while avoiding excessive deformation of the iron core laminates, thus maintaining both sealing reliability and manufacturing precision.
Solution Approach 2:
The die structure incorporates localized pressurizing portions that concentrate pressurizing force only at areas where magnet insertion holes are present. This ensures resin is effectively sealed at the holes without applying excessive force to the entire iron core, preventing deformation and maintaining end surface planarity.
2Reliability
If a large pressurizing force is applied to close gaps between laminates, then resin leakage into gaps is reduced, but stacking height varies excessively
Solution Approach 1:
The pressurizing action is segmented to occur only at locations corresponding to magnet insertion holes, rather than applying uniform pressure across the entire iron core. This localized approach effectively seals resin at critical points while minimizing overall compression of the laminate stack, thereby maintaining consistent stacking height.
Solution Approach 2:
The die includes localized pressurizing portions that apply force only where needed (at magnet insertion hole positions). This selective pressurization closes gaps locally to prevent resin leakage while avoiding excessive compression of the entire laminate stack, thus maintaining stacking height consistency.
3Reliability
If a large pressurizing force is applied during resin curing, then resin leakage is prevented, but stress is created causing resin peeling or cracking
Solution Approach 1:
The pressurizing force is applied segmentally at multiple discrete locations corresponding to magnet insertion holes rather than as a single large force. This distributes the stress locally, preventing resin leakage while avoiding the creation of excessive stress that would cause peeling or cracking.
Solution Approach 2:
The die structure provides localized pressurizing portions that apply force only at magnet insertion hole positions. This ensures adequate pressure for resin sealing while avoiding excessive stress in other areas, preventing resin peeling and cracking and maintaining bonding integrity.
Data Source
AI summary
A magnet embedded core is manufactured in a stable manner by preventing an excessive pressurizing force from being applied to the laminated iron core and performing the clamping with an appropriate pressurizing force so that the leakage of the resin out of the magnet insertion holes can be minimized, and the reduction in the geometric and dimensional precision of the laminated iron core may be suppressed. An electric die clamping device is used, such that a laminated iron core is placed on one of a fixed die and a moveable die and upon clamping by the die clamping device, the other of the fixed die and the moveable die is caused to abut onto an end surface of the laminated iron core to close openings of magnet insertion holes and pressurize the laminated iron core in a laminating direction.