Ring Light Heating for Motor Core Temperature Uniformity
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Solution Overview
Problem
Existing methods for preheating motor cores before resin filling are inefficient in achieving uniform temperature across the cylindrical outer peripheral surface, particularly around magnet insertion holes, and lack integration with the manufacturing process for automation.
Innovation Solution
A heating apparatus with ring-shaped light sources and a reflecting surface within a cylindrical covering member, along with a light shielding mechanism, is used to uniformly heat the motor core and its holding jig, allowing for independent control of light sources to prevent thermal deformation and ensure efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heating methods are used for motor cores, then heating can be performed, but uniform temperature distribution across the cylindrical outer peripheral surface is difficult to achieve
Solution Approach 1:
The heating system is divided into multiple independent heating units arranged around the motor core. Each heating unit can be independently controlled to provide localized heating, ensuring uniform temperature distribution across the entire cylindrical outer peripheral surface of the motor core.
Solution Approach 2:
Different regions of the motor core receive customized heating based on their specific requirements. The heating units are positioned and controlled to provide appropriate heat distribution to different sections of the cylindrical outer peripheral surface, achieving uniform temperature across the entire surface.
2Productivity
If heating speed is increased to improve production efficiency, then productivity increases, but temperature uniformity may deteriorate
Solution Approach 1:
The motor core is divided into multiple heating zones with independent heating units. Each zone can be heated simultaneously at high speed while maintaining uniform temperature distribution through independent control of each heating unit, resolving the conflict between heating speed and temperature uniformity.
Solution Approach 2:
Multiple heating units operate simultaneously and continuously around the motor core, providing sustained heating action across all zones. This continuous parallel heating enables both high heating speed and uniform temperature distribution to be achieved together.
3Manufacturing precision
If preheating process is added to ensure proper resin filling, then resin filling quality improves, but production time increases
Solution Approach 1:
The motor core is preheated to the required temperature before resin injection using the multi-zone heating system. This preliminary heating action ensures the motor core reaches optimal temperature for resin filling, improving filling quality while the efficient parallel heating minimizes the time penalty.
Solution Approach 2:
Conventional slow mechanical heating methods are replaced with a sophisticated multi-zone thermal field control system that uses multiple heating units with independent control. This substitution enables rapid preheating that maintains temperature uniformity, reducing preheating time while ensuring resin filling quality.
4Ease of operation
If manual preheating process is used, then temperature control can be adjusted, but automation level remains low
Solution Approach 1:
Temperature sensors are installed in each heating zone to detect the actual temperature. The detected temperature information is fed back to the control system, which automatically adjusts the heating power of each unit to maintain the target temperature. This feedback control enables both temperature control flexibility and high automation level.
Solution Approach 2:
The heating system automatically monitors and adjusts its own operation through the feedback control mechanism. Each heating unit self-regulates its power output based on temperature sensor readings, eliminating the need for manual intervention while maintaining precise temperature control flexibility.
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 solution enables quick and uniform heating of motor cores, ensuring the resin material reaches the target temperature uniformly around magnet insertion holes, enhancing production efficiency and allowing for in-line integration with the manufacturing process.
Implementation Method 1
a plurality of ring-shaped light sources each provided to surround the cylindrical outer peripheral surface of the object to be heated and arranged in a vertical direction in the accommodating space and radiating light for heating the object to be heated
Implementation Method 2
the inner wall surface of the covering member is provided with a reflecting surface for reflecting the light from the plurality of ring-shaped light sources toward the object to be heated
Data Source
AI summary
A heating apparatus for heating an object having a cylindrical outer peripheral surface includes: a support member for supporting the object to be heated; a covering member movable in the vertical directions relative to the support member and having inner wall surfaces with an open lower end, the inner wall surfaces defining an accommodation space for accommodating the object to be heated; the covering member closing the accommodation space when the covering member is disposed on the support member; the covering member allowing loading or unloading of the object to be heated when the covering member is separated from the support member; and a plurality of ring-shaped light sources each provided to surround the cylindrical outer peripheral surface of the object to be heated and arranged in the vertical direction in the accommodation space and radiating light for heating the object to be heated.