Rotor Magnet Bonding by Roll-Dip Resin Insertion
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Solution Overview
Problem
Existing methods for fixing permanent magnets in rotor laminated cores of permanent magnet dynamoelectric machines are inefficient, leading to positional inaccuracies, adhesive capillary issues, uncontrollable adhesive flow, and increased manufacturing costs due to complex and time-consuming processes, which can result in demagnetization and rotor imbalance.
Innovation Solution
A roller immersion process is used to insert permanent magnets into laminated cores, followed by a resin bath to evenly distribute adhesive in the adhesive gaps, ensuring complete bonding and minimizing capillary action, with controlled parameters like viscosity and temperature to optimize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive is applied to bond permanent magnets in rotor laminated cores using conventional methods, then bonding is achieved, but adhesive capillaries into spaces between laminations cause insufficient bonding and uncontrolled adhesive flow
Solution Approach 1:
The patent changes the physical parameters of the adhesive by adding viscosity modifiers and surfactants to control capillary action. The modified adhesive has optimized viscosity to prevent excessive capillary penetration into lamination spaces while maintaining adequate bonding flow, directly resolving the contradiction between bonding precision and process complexity
Solution Approach 2:
The patent introduces a specialized adhesive formulation as an intermediary substance between the permanent magnets and laminated core. This modified adhesive acts as a mediator that controls its own flow characteristics through chemical additives, preventing uncontrolled capillary action while ensuring proper bonding, thus improving manufacturing precision without increasing process complexity
2Reliability
If high temperature thermal treatment is applied to cure reactive resin, then complete bonding is achieved, but partial demagnetization of permanent magnets occurs
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive by incorporating low-viscosity resins and catalysts that enable curing at reduced temperatures. This parameter modification allows the bonding process to proceed reliably without subjecting permanent magnets to high temperatures that would cause demagnetization, thus maintaining both bonding reliability and magnetic properties
Solution Approach 2:
The patent replaces the thermal curing mechanism with a chemical curing mechanism using two-component reactive adhesives that cure through chemical reaction rather than thermal treatment. This substitution eliminates the need for high-temperature exposure, preventing demagnetization while achieving complete and reliable bonding through chemical cross-linking at lower temperatures
3Ease of manufacture
If paste-like adhesive is applied and displaced by permanent magnet insertion, then bonding occurs, but positional inaccuracy and localized bonding result
Solution Approach 1:
The patent changes the rheological parameters of the adhesive by formulating it with specific viscosity and flow characteristics that allow it to remain stationary during magnet insertion. The modified adhesive has controlled viscosity to prevent displacement by the magnet while maintaining adequate flow for complete gap filling, thereby achieving both manufacturing ease and positioning precision
Solution Approach 2:
The patent applies the adhesive to the laminated core surface before magnet insertion, allowing it to initially set or be positioned in advance. This preliminary action ensures the adhesive is in the correct location and orientation before the magnet is inserted, preventing positional inaccuracy while maintaining the simplicity of the manufacturing process
4Reliability
If reactive resin encapsulation is used to fix permanent magnets, then complete bonding is achieved, but time-consuming heating and cooling cycles are required
Solution Approach 1:
The patent replaces thermal curing with chemical curing using two-component reactive adhesives. The adhesive cures through chemical reaction upon mixing, eliminating the need for time-consuming heating and cooling cycles in ovens. This substitution maintains bonding reliability through complete chemical cross-linking while dramatically reducing process time by removing thermal treatment steps
Solution Approach 2:
The patent enables continuous bonding operation by using adhesives that cure through chemical reaction rather than thermal treatment. The chemical curing process occurs continuously as the adhesive is applied and mixed, without interruption for heating and cooling cycles. This continuous action maintains bonding reliability while eliminating time losses associated with thermal processing cycles
5Reliability
If adhesive is applied to seal rotor surfaces, then adhesive containment is achieved, but additional heating and cooling cycles are required
Solution Approach 1:
The patent replaces thermal curing with chemical curing for the adhesive used to seal rotor surfaces. The adhesive cures through chemical reaction without requiring heating and cooling cycles, maintaining reliable adhesive containment while eliminating the time-consuming thermal processing steps. This substitution applies the same efficient curing mechanism used for magnet bonding to the sealing function
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 achieves uniform adhesion, reduces manufacturing time and costs, minimizes demagnetization risks, and enhances rotor stability, resulting in a rotor that meets efficiency standards and operates with reduced torque ripple and vibrations.
Implementation Method 1
the adhesive capillaries from the bonding gap into the spaces between the laminations during the bonding process
Implementation Method 2
the adhesive capillaries from the bonding gap into the spaces between the laminations during the bonding process
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to methods for fixing permanent magnets (9) in rotors (4) of permanent-excited synchronous machines by means of roller immersion through the following steps: - Stacking (30) a laminated core (6) of the rotor (4), - Connecting the laminated core (6) to a shaft (8) in a rotationally fixed manner, - Inserting permanent magnets (9) axially into substantially axially extending recesses (11) of the laminated core (6), - The laminated core (6) equipped with permanent magnets (9) is immersed in a one-component resin bath (16) while rotating about its axis (7), so that the resin orAdhesive (47) is evenly distributed in the adhesive gaps (18, 20) between the permanent magnet (9) and the inside of the pocket (12), as well as between the laminations in the radially outer area of the laminated core, - then the rotor (4) is moved out of the resin bath (16), whereby the rotation continues at the same or a different speed for a predetermined time even outside the resin bath (16) until the excess resin (47) has dripped off and the gelation process is complete.