Rotor Magnet Fixation via Automatic Injection Grooves
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Solution Overview
Problem
Existing rotor manufacturing processes are time-consuming and involve multiple steps due to the need for manual injection of silicon and the use of shims, which can lead to inefficiencies and incomplete sealing, affecting the positioning and fixation of permanent magnet pieces.
Innovation Solution
A rotor design featuring a rotor iron core with slots and end plates that include cutout portions and injection openings, allowing for the automatic injection of seal material through communicating grooves to securely fix permanent magnet pieces to the outer peripheral side, reducing manufacturing time and processes while ensuring proper sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual injection of silicon and use of shims is used to fix permanent magnet pieces, then the magnet pieces can be fixed, but the manufacturing time increases and the number of processes increases
Solution Approach 1:
The patent removes the shim component entirely from the fixation process. Instead of using shims to manually push magnet pieces outward, the design uses the elastic deformation of the mold resin portion itself to achieve the same effect, thereby eliminating an extra manufacturing step and reducing overall process time while maintaining reliable fixation.
Solution Approach 2:
The mold resin portion serves multiple functions: it acts as both the bonding agent that secures the magnet piece to the rotor core and as the elastic element that pushes the magnet piece outward during assembly. This multi-functionality eliminates the need for separate shim components and manual intervention, streamlining the manufacturing process.
2Reliability
If manual injection of silicon and shims are used, then magnet pieces can be fixed, but the number of processes increases
Solution Approach 1:
The patent combines the bonding function and the positioning function into a single integrated system. The mold resin portion simultaneously bonds the magnet piece to the rotor core and provides elastic deformation to position the magnet piece outward, merging what were previously separate functions (shim for positioning, silicon for bonding) into one unified mechanism.
Solution Approach 2:
The shim component is completely removed from the process. The patent achieves the positioning function that shims provided through the elastic deformation of the mold resin portion itself, thereby reducing the number of manufacturing steps and simplifying the overall process while maintaining reliable fixation.
3Reliability
If end plates with shim insertion inlets and injection inlets are used, then magnet pieces can be fixed, but the sealing is insufficient and automation is difficult
Solution Approach 1:
The mold resin portion is pre-formed with a cavity that precisely matches the magnet piece geometry. This preliminary preparation ensures that when the magnet piece is inserted, the resin automatically deforms elastically to provide both bonding and positioning forces, achieving precise sealing and fixation without requiring additional shims or complex injection procedures through multiple inlets.
4Reliability
If silicon is injected by dropping naturally through injection inlet, then fixation can be achieved, but the injection process is slow and cannot be automated
Solution Approach 1:
The mold resin portion performs the positioning function automatically through its own elastic deformation when compressed by the magnet piece insertion. This self-service mechanism eliminates the need for manual shim insertion and natural silicon dropping, enabling automated production while maintaining reliable fixation.
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 design reduces manufacturing time and process complexity, ensures stable fixation of permanent magnet pieces, prevents wobbling, and enhances motor efficiency by allowing for precise and uniform positioning of the magnet pieces.
Implementation Method 1
both side surfaces 101a are pressed by a reaction force due to an elastic compression of the mold resin portions 104
Implementation Method 2
the seal material is injected under pressure through the injection opening
Data Source
AI summary
A rotor is provided. The rotor includes a rotor iron core including slots formed around an outer circumferential portion thereof; magnet pieces which are inserted into the slots, respectively, such that a magnetic orientation of the magnet pieces are inverted every predetermined number of the slots; and two end plates, one end plate disposed on each end side in an axial direction of the rotor iron core, the two end plates covering the slots in the axial direction. The rotor iron core also includes cutout portions, which are located at an interval between adjacent ones of the slots, each of the cutout portions extending in the axial direction of the rotor iron core. One of the two end plates includes injection openings, each of which corresponds to a respective one of the slots, and communicating grooves each of which is formed so as to communicate with one of the cutout portions.