Rotor Magnet Resin Fixing with Preheated Core Curing
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Solution Overview
Problem
The existing rotor manufacturing method for rotary electric machines faces issues with resin leakage between stacked steel sheets due to the long molten resin stay period before curing, which can lead to incomplete embedding of magnets and reduced rotor performance.
Innovation Solution
A rotor manufacturing method involving a thermosetting resin that is solid at room temperature, liquefied by heating to a melting start temperature, and cured by being heated to a curing start temperature, with specific steps for temperature increase, resin injection, and magnet fixing to prevent resin leakage between stacked steel sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rotor core is preheated and the resin is injected into the holes of the rotor core, then the magnets are fixed to the rotor core, but the resin leaks from the gap between the stacked steel sheets when the stay period of the molten resin is long
Solution Approach 1:
The rotor core is preheated to the curing start temperature or higher before resin injection. This preliminary heating action ensures that the resin begins to cure immediately upon contact with the rotor core holes, preventing resin leakage during the injection process while maintaining complete magnet embedding quality
2Quantity of substance
If the resin is injected at room temperature, then the resin remains liquid for a longer period, but the resin leaks between the stacked steel sheets before curing
Solution Approach 1:
The temperature parameter of the rotor core is changed to the curing start temperature or higher before resin injection. This parameter change causes the resin to cure rapidly upon contact with the heated rotor core holes, eliminating resin leakage while ensuring complete magnet embedding
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
The method effectively prevents resin leakage and ensures complete curing of the resin within the rotor core, enhancing the embedding of magnets and improving the rotor's performance and efficiency.
Implementation Method 1
a thermosetting resin having a characteristic that the resin is solid at room temperature, liquefied by being heated to a melting start temperature or higher
Implementation Method 2
cured by being heated to a curing start temperature or higher
Data Source
AI summary
A rotor manufacturing method for manufacturing a rotor of a rotary electric machine by disposing magnets in hole portions of a rotor core formed of stacked steel sheets, and injecting and curing a thermosetting resin to fix the magnets to the rotor core includes a temperature increasing step for increasing a temperature of the rotor core to a curing start temperature or higher, a resin injection step for causing a resin injection apparatus to inject the liquid resin at a melting start temperature or higher into the hole portions of the rotor core at the curing start temperature or higher, and a magnet fixing step for curing the resin by keeping the rotor core at the curing start temperature or higher.