Rotor Core Clamping Position Control Without Master Workpieces
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Solution Overview
Problem
The existing rotor manufacturing process is complicated by the need to switch between cores of different thicknesses, requiring the use of a master workpiece to detect and store the clamping position, which increases complexity and requires high-accuracy master workpieces for each core type.
Innovation Solution
A method for manufacturing a rotor that involves controlling the thickness of the rotor core to a specified range, detecting the clamping position of the movable die using the controller, and storing this position in memory for each type of rotor core, allowing for accurate clamping without the need for a master workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a master workpiece is used to detect and store the clamping position for each core type, then the clamping position can be accurately detected, but the manufacturing process becomes complicated and requires preparation of high-accuracy master workpieces
Solution Approach 1:
The patent replaces the master workpiece (a physical copy requiring high manufacturing accuracy) with a digital copy stored in memory. The clamping position data is saved as numerical information, eliminating the need to physically manufacture and store master workpieces for each core type. This digital copying approach maintains measurement precision while significantly reducing process complexity.
Solution Approach 2:
The patent replaces the mechanical master workpiece system with an electronic information storage and retrieval system. Instead of using physical master workpieces to define clamping positions, the system uses a sensor to detect the actual clamping position, converts it to electrical signals, and stores it in memory. This substitution eliminates the need for mechanical master workpieces and their associated manufacturing complexities.
2Manufacturing precision
If master workpieces are prepared for each core type, then accurate clamping can be achieved, but the preparation time and resources increase
Solution Approach 1:
The patent stores clamping position information as digital data in memory rather than requiring physical master workpieces. When switching between core types, the system simply retrieves the corresponding clamping position data from memory, eliminating the time-consuming process of preparing physical master workpieces for each core type while maintaining clamping accuracy.
Solution Approach 2:
The patent performs preliminary detection and storage of clamping positions during the actual manufacturing process rather than requiring separate preparation of master workpieces. The clamping position is detected using a sensor during normal operation and stored in memory for future use, converting a preparation activity into an integrated process step that occurs automatically.
3Loss of information
If the clamping position is detected using a master workpiece, then the position can be stored in memory, but the system requires additional components and setup
Solution Approach 1:
The patent replaces the master workpiece-based detection system with a sensor-based detection system that directly measures the clamping position. The sensor converts the physical clamping position into electrical signals that are processed and stored in memory. This substitution eliminates the need for master workpieces and their associated support structures, reducing system complexity while maintaining data retention capability.
Data Source
AI summary
A method for manufacturing a rotor includes controlling a thickness of a rotor core, placing the rotor core on a fixed die or a movable die of a plastic filling device after controlling the thickness of the rotor core, clamping the rotor core by moving the movable die vertically to a clamping position, and filling an insertion hole of the rotor core with a plastic. The clamping of the rotor core includes, when clamping, for the first time, a rotor core of a type different from a rotor core clamped immediately prior, detecting whether the rotor core of the different type is in a clamped state, storing, in a memory, the position of the movable die in the vertical direction at the time when the rotor core is detected to be in the clamped state as the clamping position, and stopping the vertical movement of the movable die.