Rotor Core Magnet Insertion Hole Segmentation for Resin Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In rotary electric machines, the inclination of permanent magnets during the manufacturing process leads to degraded motor efficiency due to improper securing, which existing technologies have not adequately addressed.
Innovation Solution
The implementation of a rotor core design with rectangular permanent magnets secured in magnet insertion holes using a bonding component, where a first space and a second space are provided around each magnet, with an injection portion and communication portions that ensure equal flow rates into both spaces, preventing biased flow and magnet inclination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resin is injected into magnet insertion holes to secure permanent magnets, then magnets are secured closer to outer or inner circumferential sides, but magnets may become inclined and motor efficiency degrades
Solution Approach 1:
The magnet insertion hole is divided into multiple cavities (first cavity, second cavity, third cavity) separated by partition walls. This segmentation allows independent control of resin flow into each cavity, enabling precise positioning of the magnet against different circumferential sides while preventing inclination through balanced support.
Solution Approach 2:
Different cavities are designed with different volumes and resin injection characteristics tailored to specific positioning needs. The first cavity positions the magnet against the outer circumferential side, the second against the inner circumferential side, and the third provides additional support. This local differentiation enables precise control of magnet position and orientation.
2Manufacturing precision
If resin flows preferentially into one cavity, then magnet is pressed against one side, but magnet inclination occurs and securing is compromised
Solution Approach 1:
The partition walls are designed to create equipotential flow conditions by ensuring that resin injected into the injection hole distributes evenly among multiple cavities. The partition structure balances the hydraulic potential, preventing preferential flow into any single cavity and thereby preventing magnet inclination during the resin injection process.
3Ease of manufacture
If magnet insertion holes are designed without partition walls, then manufacturing is simpler, but resin flow control is poor and magnet inclination occurs
Solution Approach 1:
The magnet insertion hole is segmented into multiple cavities by partition walls, transforming a simple unpartitioned structure into a controlled multi-chamber system. This segmentation enables precise resin flow control to different regions, achieving accurate magnet positioning while maintaining a relatively simple overall structure that can be manufactured using conventional techniques.
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 design effectively secures permanent magnets without inclination, enhancing motor efficiency by ensuring precise contact with the inner wall surface and reducing stress concentration, thereby preventing short circuits and damage to the rotor core.
Implementation Method 1
rectangular permanent magnets secured in magnet insertion holes with a bonding component
Data Source
AI summary
A rotor core has a rotational axis. A permanent magnet has a polygonal shape viewed along the rotational axis. The rotor core includes a magnet insertion hole defined by an inner wall. The polygonal shape includes first to third sides. The magnet insertion hole includes: a first space provided between the first side and the inner wall; a second space provided between the second side and the inner wall; and an injection portion, a first communication portion, and a second communication portion provided between the third side and the inner wall; viewed along the rotational axis. The first communication portion and the second communication portion connect the injection portion to the first space and the second space, respectively. The first communication portion has a first length along the third side. The second communication portion has a second length along the third side which is equal to the first length.