Rotor Manufacturing via Dual Injection Molding for Magnetization
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Solution Overview
Problem
Conventional spoke type permanent magnet motors face inefficiencies in magnetization due to the spacing between magnets and magnetizers during injection molding, leading to reduced motor performance.
Innovation Solution
A rotor manufacturing method involving dual injection molding, where the first molding supports the rotor assembly before magnetization and the second molding supports it after magnetization, allowing for precise magnetization and improved magnetic flux density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If magnets are accommodated in a mold during injection molding, then the molding process can be completed, but the magnets cannot be magnetized to desired strength due to spacing between magnetizer and magnets
Solution Approach 1:
The molding process is divided into two separate stages: first injection molding to form the rotor core and support structure, and second injection molding after magnetization to complete the assembly. This segmentation allows the magnets to be magnetized to full strength before the final molding step, resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The magnets are magnetized before the second injection molding step, performing the critical magnetization action in advance. This preliminary action ensures that the magnets achieve desired strength while still allowing the molding process to proceed, resolving the contradiction between magnetization quality and process complexity.
2Reliability
If magnets are alternately disposed with rotor cores during injection molding, then the rotor structure can be formed, but motor performance is reduced due to insufficient magnetization
Solution Approach 1:
The magnets are magnetized to full strength before the second injection molding step, performing the critical magnetization action in advance. This ensures that the alternating arrangement of magnets and rotor cores achieves the desired motor performance while maintaining ease of manufacture through the two-stage process.
Solution Approach 2:
The alternating arrangement of magnets and rotor cores is maintained continuously through both molding stages, ensuring that the useful magnetic structure is preserved while enabling proper magnetization. This continuous arrangement maintains motor performance reliability without compromising manufacturability.
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 method enables effective magnetization of magnets within the rotor, enhancing the motor's performance by ensuring stronger magnetic fields and higher torque output.
Implementation Method 1
a rotor manufactured by dual injection molding in which first injection molding is partially performed at a plurality of magnets in an unmagnetized state and rotor cores alternately disposed with the plurality of magnets, and second injection molding is performed at the entire rotor after the magnets are magnetized
Implementation Method 2
a plurality of permanent magnets radially disposed about a rotation axis... The magnets were magnetized after being injection molded
Implementation Method 3
The rotor is configured to electromagnetically interact with the stator, and rotates by a force acting between a magnetic field and current flowing in a coil
Data Source
AI summary
Disclosed herein are a rotor and a method of manufacturing the rotor. The rotor includes a rotor assembly including magnets and rotor cores, and a molding unit including a first molding unit disposed by being firstly injection molded to support the rotor assembly before the magnets are magnetized and a second molding unit disposed by being secondly injection molded to support the rotor assembly after the magnets are magnetized.