Rotary Electrical Machine Housing Boundary Paint Peeling
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Solution Overview
Problem
The existing manufacturing processes for rotary electrical machines face increased takt time and manufacturing costs due to paint peeling issues at the boundary parts of painted and machined surfaces, requiring additional repair time and resources.
Innovation Solution
The design incorporates a second housing member with a recess and specific surface roughness to cover the boundary area between painted and machined surfaces, reducing the likelihood of paint peeling and enhancing waterproof performance by creating a gap and contact between certain surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the manufacturer machines the painted end surfaces of support members after painting, then masking becomes unnecessary and manufacturing cost is reduced, but paint peeling occurs at the boundary part of the paint surface with the machining surface
Solution Approach 1:
The support member is divided into two distinct surfaces: a paint surface that receives coating and a machining surface that undergoes precision machining. By separating these functions into distinct areas, the patent avoids the paint peeling problem that occurs when machining is performed on painted surfaces, while still allowing post-painting machining to eliminate masking steps.
Solution Approach 2:
Different surface treatments are applied to different regions of the support member. The end surface is designated as a machining surface with specific geometric features (such as a stepped structure) that prevent paint application, while adjacent surfaces receive paint coating. This local differentiation ensures that machining operations do not affect painted areas.
2Shape
If the rotor support member and stator support member are both painted and their end surfaces are machined to establish contact, then the appearance of the motor is formed, but additional masking parts are required increasing takt time
Solution Approach 1:
The machining surface is prepared in advance with specific geometric features (such as a stepped structure or protrusion) that clearly define the boundary between painted and machined areas. This preliminary preparation eliminates the need for masking during the painting process, as the machining surface geometry itself prevents paint application while ensuring proper contact between support members.
3Reliability
If paint is applied to the support member surfaces before machining, then the surfaces are protected, but paint peeling occurs at the boundary part requiring repair
Solution Approach 1:
The support member surface is segmented into a paint surface and a machining surface, with a clear boundary between them. The machining surface includes geometric features (such as a stepped structure) that prevent paint application, thereby eliminating the boundary area where paint peeling typically occurs and reducing repair requirements.
Data Source
AI summary
A rotary electrical machine of the present invention comprises a housing including: a first member with a paint surface with paint and a machining surface adjoining the paint surface after being subjected to machining, the paint surface including a boundary area formed at a boundary part with the machining surface; and a second member covering the boundary area.