Rotor Magnet Insertion with Guide-Assisted Sheet Positioning
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Solution Overview
Problem
Existing rotor manufacturing methods face challenges in preventing sheets from being bent or chipped when inserted into magnet insertion holes with minute irregularities, as the tip end portion of the sheet can be caught by the inner surface irregularities during insertion.
Innovation Solution
A rotor manufacturing method and apparatus that involves directing a rod-like guide into the magnet insertion hole, inserting sheets along the guide's side surfaces, and then pulling out the guide to allow the sheets to widen and support the permanent magnet, which is then inserted, while also employing sheets that expand by heating to secure the magnet and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sheet is inserted into the magnet insertion hole independent of the permanent magnet, then the sheet can be positioned before magnet insertion, but the tip end portion of the sheet is caught by the irregularities of the inner surface and bent or chipped
Solution Approach 1:
A guide member is introduced as an intermediary tool between the sheet and the magnet insertion hole. The guide member has a smooth surface that prevents the sheet's tip end from being caught by irregularities on the hole's inner surface. The sheet is inserted along the guide member's surface, which acts as a protective mediator during the insertion process, thereby maintaining sheet integrity while achieving precise positioning.
Solution Approach 2:
The guide member is inserted into the magnet insertion hole before the sheet is inserted. This preliminary action prepares the insertion path by establishing a smooth guide surface, preventing potential damage to the sheet before it even contacts the irregular inner surface of the hole. The guide member remains in place during sheet insertion to ensure continuous protection.
2Strength
If adhesive is coated on the sheet to fix the permanent magnet, then the magnet can be secured in the hole, but the adhesive requires curing time and additional processing steps
Solution Approach 1:
The fixing mechanism transitions from chemical bonding (adhesive curing) to mechanical interlocking. The sheet's tip end is inserted into a groove formed in the permanent magnet, creating a mechanical lock that secures the magnet without requiring adhesive curing time. This parameter change from chemical to mechanical fixation eliminates the waiting period for adhesive to set.
Solution Approach 2:
The adhesive layer and its curing process are extracted from the fixation mechanism. Instead of relying on adhesive coating and curing, the solution uses a mechanical groove structure that provides immediate fixation. This removes the time-consuming adhesive application and curing steps from the manufacturing process.
3Productivity
If multiple sheets are inserted from above the rotor core, then all sheets can be positioned simultaneously, but the sheets may become misaligned or tangled during insertion
Solution Approach 1:
The simultaneous insertion of multiple sheets is segmented into individual insertion paths guided by separate guide members. Each guide member independently guides one sheet along its specific trajectory, preventing sheets from interfering with each other. This segmentation maintains both high productivity through parallel processing and precise alignment through dedicated guidance for each sheet.
Solution Approach 2:
The insertion process utilizes three-dimensional space by having sheets approach the magnet insertion hole from different angular directions. Each sheet is guided along a unique spatial path defined by its corresponding guide member, allowing multiple sheets to be inserted simultaneously without tangling while maintaining precise alignment through spatial separation of insertion trajectories.
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
Prevents sheet bending or chipping by guiding the sheets along the guide's surfaces, ensuring they are not caught by the magnet insertion hole irregularities, and allows for secure magnet fixation and insulation, enhancing the manufacturing process's reliability and efficiency.
Implementation Method 1
employing sheets that expand by heating to secure the magnet and prevent damage
Data Source
AI summary
A rotor manufacturing method comprises an arranging step for arranging a rotor core, which is formed by stacking electromagnetic steel plates, to direct the stacked electromagnetic steel plates toward a vertical direction, a guide inserting step for inserting a rod-like guide into a magnet insertion hole formed to extend in the stacked direction of the rotor core after the arranging step, a sheet inserting step for inserting a plurality of sheets from above the rotor core into the magnet insertion hole along different side surfaces of the guide after the guide inserting step, a guide pull-out step for pulling out the guide from the magnet insertion hole after the sheet inserting step, and a magnet inserting step for inserting a permanent magnet between the plurality of sheets within the magnet insertion hole after the guide pull-out step.