Rotor Can Mechanical Interlocking Eliminates Adhesive
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Solution Overview
Problem
The assembly process of electric power steering (EPS) system rotors is complicated due to the need for adhesive application and the use of multiple cans, which increases manufacturing costs and complexity.
Innovation Solution
A rotor design that includes a rotor core, a cover, and a can member with protrusion portions and stoppers, eliminating the need for adhesive by combining the can member with the cover, thereby increasing the combinational force and reducing the number of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied to assemble the rotor inside the can, then the magnets are protected and the rotor is assembled, but the assembly process becomes complicated and manufacturing efficiency decreases
Solution Approach 1:
The patent replaces the chemical bonding method (adhesive) with a mechanical bonding method. The can member includes protrusion portions that engage with corresponding grooves on the rotor core, creating a mechanical interlocking structure that eliminates the need for adhesive application while maintaining assembly reliability.
Solution Approach 2:
The patent changes the bonding mechanism from chemical (adhesive) to mechanical (protrusion-groove engagement). The protrusion portions are designed with specific dimensions and engagement angles that provide sufficient holding force without requiring adhesive, thereby simplifying the assembly process while maintaining durability.
2Ease of manufacture
If adhesive application process is used, then the rotor can be assembled inside the can, but the number of assembly steps increases and manufacturing costs increase
Solution Approach 1:
The mechanical protrusion-groove engagement structure eliminates the adhesive application step entirely. The protrusion portions are formed as integral parts of the can member, and the grooves are formed on the rotor core, allowing for direct mechanical assembly without additional chemical processing steps.
3Reliability
If two cans are used to protect the rotor, then the magnets are well protected, but the number of components increases and manufacturing costs increase
Solution Approach 1:
The patent merges the protective can structure with the assembly fixation structure into a single integrated component. The can member includes both the protective cylindrical body and the protrusion portions for mechanical engagement, eliminating the need for separate protective cans while maintaining both protection and assembly reliability.
Solution Approach 2:
The can member is designed to serve multiple functions simultaneously: it protects the magnets from external damage and provides mechanical engagement with the rotor core through its protrusion portions. This multi-functional design eliminates the need for separate protective components.
Data Source
AI summary
The present invention provides a rotor comprising: a rotor core; a cover arranged on an upper part of the rotor core; a magnet arranged on the outer circumferential surface of the rotor core; and a can member accommodating the rotor core and the magnet and coupled to the cover, wherein the cover includes a plurality of downwardly extending guides, the guides are arranged on the outer circumferential surface of the rotor core and are arranged inside the can member, and the can member includes at least one protrusion part protruding from a border thereof so as to be coupled to the cover. Therefore, the present invention provides an advantageous effect of excluding the use of an adhesive in the coupling of a can to a rotor core.