Rotor Core Welding Segmentation for Thin Steel Sheet Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rotors face issues with insufficient joining of the core to the shaft, leading to potential deformation and core opening due to welding heat, especially with thin magnetic steel sheets, which affects the rotor's stability and performance.
Innovation Solution
A rotor design featuring a core with a through hole for the shaft, where inner-peripheral-side welding joins the magnetic steel sheets to the shaft, and outer-peripheral-side welding joins the sheets at the end faces, preventing slippage and deformation while minimizing the impact on the electromagnetic circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic steel sheets are welded to the shaft over the laminating direction, then the core is securely fixed to the shaft, but the welding heat causes deformation and warping of the thin steel sheets
Solution Approach 1:
The welding process is divided into two distinct stages: first welding the steel sheets to each other on the inner peripheral side, then welding the core end face to the shaft. This segmentation allows each welding operation to be optimized independently, preventing excessive heat accumulation that would cause deformation while ensuring secure fixation.
Solution Approach 2:
The steel sheets are preliminarily welded to each other on the inner peripheral side before the core is welded to the shaft. This preliminary action creates a stable laminated structure that can better withstand the subsequent welding heat, preventing warping and maintaining manufacturing precision.
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 configuration ensures a stable and secure fixation of the rotation transmitting member to the core, preventing core opening and maintaining the rotor's performance and power efficiency by controlling the welding process and placement of welded sections.
Implementation Method 1
an inner-peripheral-side welded part provided on an inner peripheral side of the core to join between the magnetic steel sheets constituting the laminated steel sheet assembly, the inner-peripheral-side welded part being a welded section that joins the laminated steel sheets to the rotation transmitting member over a laminating direction of the magnetic steel sheets
Implementation Method 2
an outer-peripheral-side welded part provided on an outer peripheral side of the core and at an end in the laminating direction, the outer-peripheral-side welded part being a welded section that joins between some of the steel sheets, including a steel sheet forming an end face of the core in the laminating direction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A rotor (100) includes a core (11) made of a laminated steel sheet assembly including a plurality of laminated magnetic steel sheets (21) each having a flat plate shape, the core (11) including a through hole (26) at a rotation center, a shaft (12) inserted in a through hole (26) of the core (11), an inner-peripheral-side welded part (29) located on an inner peripheral side of the core (11), the welded part (29) being a welded section joining between adjacent steel sheets (21) and joining the laminated steel sheet assembly to the shaft (12) over a laminating direction, and an outer-peripheral-side welded part (32) located on an outer peripheral side of the core (11) and in an end part in the laminating direction, the welded part (32) being a welded section joining between some of the magnetic steel sheets (21), the joined steel sheets including a steel sheet (21U) forming an end face of the core (11) in the laminating direction.