Magnet Cover Rotor Assembly With Load Block Caulking Protection
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Solution Overview
Problem
Existing rotor designs face issues with permanent magnet damage or deterioration due to excessive caulking loads, particularly when the magnet cover is fixed to the rotor core, which can lead to assembly strength deficiencies and potential damage to the permanent magnets.
Innovation Solution
A rotor configuration that includes a load reception block positioned between the flange part and the rotor core, with the flange part being caulked to secure the magnet cover, thereby minimizing direct caulking loads on the permanent magnets, and additional features like annular parts, legs, and locking claws to regulate displacement and position the magnets accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the magnet cover is fixed to the rotor core by caulking, then assembly strength is improved, but the permanent magnet may be damaged or deteriorated due to large caulking loads
Solution Approach 1:
The patent introduces a load reception block as an intermediary component positioned between the flange part of the magnet cover and the rotor core. This block reception block receives and distributes the caulking load, preventing direct transmission of large caulking forces to the permanent magnet, thereby resolving the contradiction between achieving strong assembly and protecting the magnet from damage
2Ease of operation
If a bent piece is arranged on the end edge of the magnet cover and locked in a hole or concavity, then assembly ease is improved, but assembly strength becomes inferior to caulking
Solution Approach 1:
The patent merges the advantages of both assembly methods by combining the load reception block (which enables strong caulking fixation) with the flange part structure (which provides assembly guidance). The flange part with bent pieces engages with holes or concavities in the rotor core to guide assembly, while the load reception block distributes caulking loads to achieve strong fixation, thus combining ease of operation with high assembly strength
Data Source
AI summary
A rotor is provided with: a rotor core (32); a plurality of permanent magnets (33); a substantially tubular magnet cover (71); and a load reception block (70). The rotor core (32) rotates integrally with a rotary shaft of a motor. The permanent magnets (33) are arranged on the outer peripheral part of the rotor core (32). The magnet cover (71) covers the exterior of the plurality of permanent magnets (33) and the rotor core (32), and has a flange part which is bent radially inward at the end along a rotation axis. The load reception block (70) is disposed between the flange part and the end surface of the rotor core (32) in a direction along the rotation axis, and abuts against the flange part and the rotor core (32).