Rotor Adhesive Application Nozzle Movement Strategy
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Solution Overview
Problem
The existing method of manufacturing rotors with permanent magnets bonded using an adhesive containing a foaming agent results in non-uniform adhesive thickness, leading to interference issues and increased manufacturing steps, as well as a larger equipment size due to the need for a press machine to form the adhesive into a sheet shape.
Innovation Solution
A method and device for applying the adhesive to the rotor core or permanent magnet, where the nozzle moves in a direction along the application surface, spreading the adhesive to a portion on the front side after the adhesive feeding is finished, preventing residual adhesive from increasing the thickness at the application end and minimizing non-uniformity, thus eliminating the need for a press machine and reducing equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the adhesive is applied with a constant discharge amount while moving the nozzle, then the application process is simple, but the adhesive thickness becomes non-uniform with thicker ends
Solution Approach 1:
The nozzle continues to move forward beyond the application area before stopping adhesive discharge, preliminarily positioning the nozzle at the front side position. This preliminary action ensures that when discharge stops, the adhesive thickness at the application end is minimized, preventing the thickening problem at the ends while maintaining simple constant discharge control throughout the process.
2Productivity
If the adhesive thickness is reduced to prevent interference, then the number of manufacturing steps is reduced, but the bonding strength may be compromised
Solution Approach 1:
The invention changes the spatial parameter of adhesive application by extending the nozzle travel distance beyond the application area. This parameter change allows the adhesive discharge to stop while the nozzle is still at the front side position, effectively reducing the adhesive thickness at the application end without reducing the overall adhesive amount or compromising bonding strength in the main application area.
3Manufacturing precision
If a press machine is used to form the adhesive into a sheet shape, then the adhesive thickness is uniform, but the equipment size increases
Solution Approach 1:
The invention extracts and eliminates the press machine from the adhesive application system. By taking out the complex pressing and heating equipment, the solution achieves uniform adhesive thickness through a simpler nozzle movement strategy, significantly reducing equipment size while maintaining manufacturing precision.
Solution Approach 2:
The adhesive application system becomes self-sufficient by using the nozzle's own movement trajectory to control adhesive thickness distribution. The nozzle continues moving forward during discharge and stops at the front side position, allowing the system to self-regulate adhesive thickness without external pressing or heating intervention, eliminating the need for additional equipment.
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 approach ensures uniform adhesive thickness, prevents interference between the adhesive and rotor components, and reduces the number of manufacturing steps by avoiding the need for adhesive removal and press machine usage, while maintaining bonding strength.
Implementation Method 1
an adhesive containing a foaming agent
Implementation Method 2
the adhesive is heated to foam and cure
Implementation Method 3
the adhesive is heated to foam and cure
Data Source
AI summary
A method of manufacturing a rotor including a rotor core and a permanent magnet that is bonded to the rotor core with an adhesive containing a foaming agent, wherein applying the adhesive includes applying the adhesive such that the adhesive is spread to a portion on a front side with respect to the application area on the application surface, by moving the nozzle to a front side in the nozzle traveling direction with respect to a position in the application area at which feeding of the adhesive by the pump is finished.