Rotor Magnet Insertion via Resonance Vibration
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Solution Overview
Problem
The challenge in manufacturing rotors for rotating electric machines is that positional deviations during the stacking of electromagnetic steel plates lead to varying opening sizes and reduced straightness, making it difficult to insert magnets efficiently due to increased contact area and insertion resistance.
Innovation Solution
A method involving the vibration of the rotor core and jig at a resonance frequency to facilitate magnet insertion, using a guiding member and adjusting the insertion direction to reduce contact area and insertion load, and incorporating positioning parts to manage in-plane displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gap between magnets and the inner wall of openings is narrowed to improve torque transmission, then magnetic field transmission efficiency is improved, but insertion difficulty increases due to increased contact area with the inner wall
Solution Approach 1:
The rotor core is vibrated at its resonance frequency during magnet insertion. This vibration temporarily increases the gap between magnets and the inner wall of openings, allowing magnets to be inserted with reduced contact area and insertion resistance, while still achieving the desired narrow gap for efficient magnetic field transmission after insertion
2Adaptability or versatility
If electromagnetic steel plates are stacked to form the rotor core, then manufacturing flexibility is improved, but opening straightness deteriorates due to positional deviation during stacking
Solution Approach 1:
Vibration at resonance frequency compensates for the positional deviations accumulated during stacking of electromagnetic steel plates. The vibration allows magnets to pass through uneven parts of the stacked plates, effectively overcoming the straightness degradation caused by stacking tolerances
Solution Approach 2:
The physical state of the rotor core is changed by applying vibrational energy at resonance frequency. This parameter change (from static to vibrated state) temporarily modifies the effective geometry of the openings, allowing magnets to be inserted despite variations in opening straightness caused by stacking
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 method allows for easier and more efficient insertion of magnets into the rotor core openings, reducing the required insertion load and preventing damage, while improving torque transmission by narrowing the gap between magnets and the inner wall.
Implementation Method 1
the magnets are inserted into the respective openings while a structure including the rotor core and the jig is vibrated at a resonance frequency of the structure
Data Source
AI summary
A method of manufacturing a rotor according to the present invention includes: a process of stacking a plurality of electromagnetic steel plates on a jig 30 to fix the electromagnetic steel plates to the jig 30, and a process of inserting magnets 21 into a plurality of respective openings 11 included in a rotor core 10 in which the plurality of electromagnetic steel plates are stacked on one another. The magnets 21 are inserted into the respective openings 11 while a structure 80 including the rotor core 10 and the jig 30 is vibrated at a resonance frequency of the structure 80.