Rotor Magnet Insertion Using Pulling Mechanism

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Solution Overview

Problem

The existing rotor manufacturing method faces issues where the insertion member can get caught in the magnet hole due to friction, leading to damage as the magnet is further pressed in, causing displacement and potential damage to the insertion member.

Innovation Solution

A method and device where a magnet is inserted into a rotor core using an insertion member with a first and second opening, allowing the magnet to be fixed to the insertion member and pulled in, ensuring integral insertion and preventing the insertion member from being caught, thus avoiding damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the magnet is pressed into the magnet hole while winding the insertion member thereon, then the magnet can be inserted into the magnet hole, but the insertion member may be caught on an inner wall due to friction, causing damage to the insertion member

Engineering Contradiction:

Improvemagnet insertion processVSAvoidinsertion member integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Instead of pressing the magnet into the magnet hole while winding the insertion member (conventional method), the patent inverts the approach by inserting the insertion member first, then fixing the magnet to the insertion member, and finally pulling the insertion member to insert the magnet. This reversal of the operation sequence eliminates the friction-induced catching problem that damages the insertion member.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent applies preliminary action by first inserting the insertion member into the magnet hole and fixing the magnet to the insertion member before performing the actual magnet insertion. This preliminary setup ensures that the magnet and insertion member are pre-positioned and secured together, preventing the insertion member from being caught during the pressing operation.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the magnet is further pressed in despite the insertion member being caught, then the magnet insertion can be completed, but displacement and damage to the insertion member occur

Engineering Contradiction:

Improvemagnet insertion completionVSAvoidinsertion member position accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent uses the insertion member as an intermediary element that connects the magnet to the pulling mechanism. By fixing the magnet to the insertion member and pulling the insertion member, the magnet is inserted without direct pressing, thereby preventing the insertion member from being caught and displaced while ensuring complete insertion.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the direct mechanical pressing system with a pulling system. Instead of applying compressive force to press the magnet into the hole, the system uses tensile force by pulling the insertion member, which has the magnet attached, to draw the magnet into the magnet hole. This substitution eliminates the friction-induced catching problem.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11637485B2Method of manufacturing rotor in which magnet is inserted into magnet hole of rotor core

Publication Date: 2023.04.25 TOYOTA JIDOSHA KK

AI summary

A method of manufacturing a rotor is disclosed. A magnet is inserted into a magnet hole of a rotor core. The method comprises inserting an insertion member into the magnet hole having a first opening and a second opening. The method comprises fixing the magnet to the insertion member extending out from the second opening. The method comprises inserting the magnet, which is fixed to the insertion member, into the magnet hole from the second opening by pulling the insertion member extending out from the first opening in a direction separating away from the rotor core. The method comprises cutting the insertion member extending out from the first opening.