Rotor Core Jig Layout for Plastic Filling and Weld Clearance
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Solution Overview
Problem
Existing rotor manufacturing apparatuses require separate jigs for plastic filling and welding steps, leading to potential welding interference and increased part count, necessitating the removal and reattachment of jigs, which can damage the rotor core.
Innovation Solution
A manufacturing apparatus with a stacking jig and cull plate configuration that allows for standardized jig use across both steps, featuring escape portions to prevent welding interference and maintain jig integrity during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a standardized jig is used for both plastic filling and welding steps, then the number of parts is reduced, but welding interference and potential damage to the rotor core occur
Solution Approach 1:
The jig is divided into two separate members: a first member that contacts one end face of the rotor core and closes first openings of magnet housing holes, and a second member that closes second openings and supplies plastic. This segmentation allows each member to be optimized for its specific function, with the first member designed to accommodate welding operations without interference while the second member handles plastic filling.
Solution Approach 2:
The first member acts as an intermediary structure during welding operations. It is positioned to close the first openings of magnet housing holes while including escape portions that allow welding to proceed without the jig interfering with the welding location. This intermediary structure protects the rotor core from damage while enabling the welding process.
2Reliability
If separate jigs are used for plastic filling and welding steps, then welding interference is avoided, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The first and second members are combined in a standardized jig assembly that can be used for both plastic filling and welding operations. The second member supplies plastic to fill magnet housing holes, while the first member simultaneously serves as a support structure during welding. This merging eliminates the need to remove and reattach different jigs, reducing manufacturing cycle time while maintaining welding quality through the escape portions.
Solution Approach 2:
The standardized jig assembly achieves multi-functionality by designing the first member to serve dual purposes: closing first openings during plastic filling and providing an escape path during welding operations. The second member handles plastic supply in both operations. This universal design allows a single jig assembly to perform both plastic filling and welding support functions without compromising either process.
3Reliability
If the jig is removed and reattached between steps, then welding interference is prevented, but the rotor core is at risk of damage and the process is simplified
Solution Approach 1:
The first member is pre-configured with escape portions at locations that correspond to welding positions on the rotor core. This preliminary design ensures that when the standardized jig is in place during welding operations, the escape portions are already positioned to allow welding to proceed without interference, eliminating the need to remove and reattach the jig between steps.
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
Enables seamless transition from plastic filling to welding without removing the jig, reducing the risk of rotor core damage and simplifying the manufacturing process by standardizing the jig for both steps.
Implementation Method 1
plastic is supplied to the second plastic supply passages of the die body, so that the magnet housing holes of the rotor core are filled with the plastic via the first plastic supply passages and the filling pots
Implementation Method 2
the iron core pieces are welded to each other so as to be coupled together
Data Source
AI summary
A manufacturing apparatus for a rotor includes a first member that is configured to contact one end face of the rotor core and close first openings of magnet housing holes, and a second member that is configured to close second openings of the magnet housing holes. The second member includes a supply portion configured to supply plastic to the second openings. A direction in which an axis of the rotor core extends is defined as an axial direction. An escape portion is provided in a portion of the first member that is configured to face, in the axial direction, a welding location at which the iron core pieces of the rotor core are to be welded to each other. The escape portion is located inward of an outer circumferential surface of the rotor core.