Rotor Core Molding with Pre-Adjusted Clamping for Stack Height Variation
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Solution Overview
Problem
Existing rotor core molding systems face limitations in handling varying stack heights, stack height variations, and process time, making them unsuitable for automated manufacturing environments and lacking quality and process control required for automotive parts production.
Innovation Solution
A rotor core molding method and system that employs a displacement mechanism with a pre-adjustment arrangement to set a preset open configuration, allowing for long-range distance movement to accommodate varying heights, and a mold closure arrangement for short-range movement to apply clamping pressure, enabling efficient processing of rotor cores with high precision and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mechanical mold press is used for molding rotor cores, then the molding process can be performed, but the system can only handle a small variation in stack heights
Solution Approach 1:
The patent employs a programmable displacement mechanism that dynamically adjusts the distance between molds based on the actual height of the rotor core stack. This dynamic adjustment capability allows the system to handle various stack heights without requiring physical conversion parts, resolving the contradiction between adaptability and device complexity
Solution Approach 2:
The system changes the operational parameter of mold distance programmatically rather than through mechanical reconfiguration. By controlling the displacement mechanism through programmed parameters, the system can adapt to different stack heights while maintaining a consistent mechanical structure, thus improving adaptability without increasing device complexity
2Adaptability or versatility
If the mold distance is fixed, then the mold press structure is simple, but it cannot accommodate varying heights of rotor core stacks
Solution Approach 1:
The patent replaces traditional mechanical adjustment mechanisms (such as interchangeable plates or manual positioning) with a programmable displacement mechanism. This substitution allows for automated, precise control of mold distance based on stack height, achieving adaptability while keeping the overall system structure relatively simple through software control rather than complex mechanical linkages
3Extent of automation
If manual adjustments are made for different stack heights, then adaptability is achieved, but processing time increases and automation is reduced
Solution Approach 1:
The system performs preliminary measurement of the stack height and pre-calculates the required mold distance before the actual molding process. This preliminary action allows the displacement mechanism to be positioned correctly in advance, eliminating the need for manual adjustments during production and enabling fully automated processing without time loss
Solution Approach 2:
The displacement mechanism automatically determines and adjusts the mold distance based on the stack being processed, without requiring external manual intervention. The system serves itself by autonomously adapting to different stack heights, thereby achieving both high automation and efficient processing time
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
The system can handle large variations in stack heights, ensuring identical processing conditions and quality, facilitating fully automated manufacturing, and adapting to different stack heights without manual adjustments, crucial for automotive parts production.
Implementation Method 1
A fluid molding material is provided into the magnet cavities of the unmolded rotor core(s) clamped between the first and second molds, which is subsequently allowed to cure within the magnet cavities
Data Source
AI summary
A rotor core molding system, for molding magnets in an unmolded rotor core to provide a molded rotor core for an electrical motor, comprises first and second molds arranged to allow clamping at least one unmolded rotor core between the molds, a pre-adjustment arrangement for allowing to pre-adjust a distance between the molds in a preset open configuration of the molds to a pre-adjusted distance, and a mold closure arrangement for allowing to close the molds from the preset open configuration to a closed configuration by moving the molds towards one another to clamp unmolded rotor core(s) provided between the molds with a predetermined pressure in between the molds in the closed configuration. The pre-adjustment arrangement is configured to provide a relatively long-range distance movement, especially corresponding to one or more rotor core heights. The mold closure arrangement is configured to provide a relatively short-range distance movement.