Rotor Core Lamination for Cooling Passage Accuracy
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Solution Overview
Problem
The existing methods for manufacturing rotor cores in rotating electric machines face challenges in maintaining the cross-sectional flow area of cooling passages while limiting positional accuracy, leading to decreased cooling efficiency due to variations in the number of stacked iron core pieces.
Innovation Solution
The method involves adjusting the number of stacked iron core pieces in core piece blocks to maintain a target lamination thickness and constant number of pieces in specific blocks, ensuring the cross-sectional flow area of cooling passages is preserved, and positional accuracy is maintained by forming core piece blocks with predetermined numbers of pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of stacked iron core pieces is adjusted to maintain positional accuracy of the cooling passage opening, then the positional accuracy improves, but the cross-sectional flow area of the cooling passage decreases
Solution Approach 1:
The rotor core is divided into multiple core piece blocks, each formed by stacking a specific number of iron core pieces. The second passage block is segmented to contain through-holes that form the second passage, while the first passage block contains through-holes forming the first passage. This segmentation allows independent optimization of each block's structure to maintain both positional accuracy and flow area.
Solution Approach 2:
Different core piece blocks are designed with different local structures: the second passage block has through-holes positioned to maintain the opening at a specified height from the lower surface, while the first passage block has through-holes positioned to maintain an appropriate gap from the second passage block. This local quality differentiation ensures that each block contributes optimally to the overall cooling passage geometry, maintaining both positional accuracy and cross-sectional flow area.
2Length of stationary object
If the number of stacked iron core pieces is increased to maintain lamination thickness, then the lamination thickness is maintained, but the cross-sectional flow area of the cooling passage decreases
Solution Approach 1:
The rotor core is divided into multiple core piece blocks, each formed by stacking a specific number of iron core pieces. The second passage block is segmented to contain through-holes that form the second passage, while the first passage block contains through-holes forming the first passage. This segmentation allows independent optimization of each block's structure to maintain both positional accuracy and flow area.
Solution Approach 2:
Different core piece blocks are designed with different local structures: the second passage block has through-holes positioned to maintain the opening at a specified height from the lower surface, while the first passage block has through-holes positioned to maintain an appropriate gap from the second passage block. This local quality differentiation ensures that each block contributes optimally to the overall cooling passage geometry, maintaining both positional accuracy and cross-sectional flow area.
3Manufacturing precision
If the number of stacked iron core pieces is adjusted to maintain positional accuracy, then the positional accuracy improves, but the cooling efficiency decreases
Solution Approach 1:
The rotor core is divided into multiple core piece blocks, each formed by stacking a specific number of iron core pieces. The second passage block is segmented to contain through-holes that form the second passage, while the first passage block contains through-holes forming the first passage. This segmentation allows independent optimization of each block's structure to maintain both positional accuracy and flow area.
Solution Approach 2:
Different core piece blocks are designed with different local structures: the second passage block has through-holes positioned to maintain the opening at a specified height from the lower surface, while the first passage block has through-holes positioned to maintain an appropriate gap from the second passage block. This local quality differentiation ensures that each block contributes optimally to the overall cooling passage geometry, maintaining both positional accuracy and cross-sectional flow area.
Data Source
AI summary
A method for manufacturing a rotor core includes forming core piece blocks and forming a block body that forms a first end face in a stacking direction of the rotor core. The forming each core piece block includes adjusting, when forming a first passage block adjacent to a second passage block, a number of stacked iron core pieces forming the first passage block such that a lamination thickness of the iron core pieces stacked from a first end face to a contact surface of the first passage block with the second passage block falls within a target range, and setting, when forming the second passage block, a number of the stacked iron core pieces forming the second passage block to a predetermined constant number.