Rotor Permanent Magnet Fixation via Expansive Adhesive
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Solution Overview
Problem
The existing rotor manufacturing method using a permanent magnet fixing method with an adhesive sheet is inefficient due to increased steps, difficulty in shaping and affixing the adhesive sheet, and issues with adhesive placement, leading to potential adhesive exudation to undesired positions.
Innovation Solution
A method involving applying a molten adhesive with an expansive agent to specific positions on the permanent magnet or rotor core, drying it, and then heating to fix the magnet in place, eliminating the need for a pressing machine or mold and preventing adhesive exudation to incorrect positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adhesive sheet is used to fix the permanent magnet, then the permanent magnet can be fixed to the rotor core, but the number of manufacturing steps increases and the adhesive sheet becomes difficult to shape and affix
Solution Approach 1:
The invention extracts the adhesive from the sheet form and applies it directly in molten state to the permanent magnet. This eliminates the separate adhesive sheet formation step and simplifies the manufacturing process while maintaining reliable fixation.
Solution Approach 2:
The invention changes the physical state of the adhesive from solid sheet to molten liquid, allowing direct application and subsequent curing. This parameter change enables the adhesive to be applied without forming a sheet first, reducing manufacturing steps.
2Manufacturing precision
If a molten adhesive is pressed by a mold during pressing, then the adhesive surface can be smoothed, but the adhesive may be exuded to positions where it should not be placed
Solution Approach 1:
The invention performs preliminary positioning of the adhesive by applying it to specific locations on the permanent magnet before the pressing operation. This preliminary action ensures the adhesive remains in the correct position and does not exude to undesired areas during pressing.
Solution Approach 2:
The invention applies adhesive with different properties to different locations - specifically applying it only where needed on the permanent magnet surface. This local quality approach prevents adhesive from reaching positions where it should not be placed.
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 approach ensures precise adhesive placement, improves insertability of the permanent magnet, reduces manufacturing steps, and prevents adhesive interference with the rotor core, enhancing the overall manufacturing process efficiency.
Implementation Method 1
the adhesive material, which contains a foaming agent that is foamed when heated, is placed on such a surface... when the adhesive material is heated, the foaming agent is foamed to expand the adhesive material
Implementation Method 2
the surface of the adhesive material is smoothed by the pressing machine pressing the adhesive material using a mold while heating the adhesive material to be cured
Data Source
AI summary
A method of manufacturing a rotor includes: applying the adhesive to an adhesive placement position on an outer peripheral surface of the permanent magnet or an inner peripheral surface of the magnet hole, the adhesive containing an expansive agent that is expanded by being heated to a temperature that is equal to or higher than an expansion temperature; drying the adhesive after applying the adhesive; inserting the permanent magnet into the magnet hole of the rotor core after drying the adhesive; and fixing the permanent magnet and the rotor core to each other using the adhesive by expanding the expansive agent and curing the adhesive by heating the adhesive to a temperature that is equal to or higher than the expansion temperature after inserting the permanent magnet.