Laminated Rotor Core Weight Imbalance Control
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Solution Overview
Problem
The manufacturing of laminated rotor cores often results in weight imbalances due to non-uniform metal sheet thickness, leading to torque fluctuations and performance issues in motors, as existing methods rely on post-lamination resin injection to adjust stacking height deviations.
Innovation Solution
A method and apparatus that measure weight imbalances of core members, determine optimal laminating conditions to adjust these imbalances during the lamination process, and optionally adjust the position or inclusion of permanent magnets and resin to minimize weight imbalances, ensuring uniform thickness and improved flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If blanked members are laminated one-by-one from metal sheets with non-uniform thickness, then the lamination process is simple and straightforward, but stacking height deviation and weight imbalance occur in the laminated rotor core
Solution Approach 1:
The patent applies preliminary action by pre-measuring the weight imbalance of each core member before lamination and determining the lamination order in advance to minimize weight imbalance. The controller pre-calculates the optimal lamination sequence based on measured weight distributions, rather than laminating in a simple sequential order. This resolves the contradiction by maintaining process simplicity while achieving precision through intelligent pre-planning of the lamination sequence.
Solution Approach 2:
The patent changes the parameter of lamination order based on measured weight imbalance data. Instead of using a fixed lamination sequence, the system dynamically adjusts which core members are laminated first, second, third, etc., based on their individual weight characteristics. This parameter change enables the system to achieve uniform stacking height and minimize weight imbalance while keeping the lamination process itself simple and automated.
2Manufacturing precision
If resin is injected into cavity holes after lamination to adjust stacking height deviation, then weight imbalance can be corrected, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by correcting weight imbalance during the lamination process itself rather than requiring post-lamination resin injection. The controller determines the lamination order in advance based on measured weight data, and by strategically selecting which core members to laminate first, the system achieves weight balance before the lamination is complete. This eliminates the need for additional resin injection equipment and processes, reducing manufacturing complexity while maintaining precision.
Solution Approach 2:
The patent extracts the weight correction function from the post-lamination resin injection process and integrates it into the lamination process itself. By using intelligent lamination sequencing based on pre-measured weight data, the system performs weight balancing as an inherent part of lamination rather than as a separate corrective step. This extraction of the correction function eliminates the need for complex resin injection apparatus and reduces overall process complexity.
3Productivity
If the lamination order is fixed and simple, then manufacturing productivity is high, but weight imbalance cannot be effectively controlled
Solution Approach 1:
The patent applies preliminary action by measuring the weight imbalance of each core member before lamination and pre-determining the optimal lamination sequence. The controller stores this weight data and uses it to automatically select the best lamination order without requiring complex real-time adjustments during the process. This preliminary preparation enables the system to achieve both high productivity (through automated sequential lamination) and precise weight balance control (through intelligent sequencing).
Solution Approach 2:
The patent implements feedback by using weight measurement data from each core member to inform the lamination sequencing decisions. The controller receives weight imbalance information, processes it to determine the optimal lamination order, and then executes that sequence. This feedback loop allows the system to automatically adjust the lamination process based on actual measured properties, achieving both high productivity and precise weight balance without manual intervention.
Data Source
AI summary
A method of manufacturing a rotor core having a plurality of core members stacked together includes determining weight imbalances for the plurality of core members with respect to a central axis of the rotor core; combining the weight imbalances of the plurality of core members to determine a weight distribution of the rotor core; and displacing the weight imbalances of one or more of the plurality of core members to adjust a position of the weight distribution of the rotor core with respect to the central axis.