Rotor Magnet Positioning via Staggered Fixing Material Injection
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Solution Overview
Problem
Existing rotor manufacturing methods face challenges in accurately positioning and fixing magnets within slots due to limitations in the directional movement and fixation of the magnet, leading to difficulties in achieving appropriate magnetic characteristics and stress distribution.
Innovation Solution
A rotor manufacturing method and apparatus that utilize multiple fixing-material-injection portions with controlled injection timing, speed, and amount to push and position the magnet, allowing for movement in multiple directions and precise placement by differing the injection parameters between these portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single fixing-material-injection portion is used to inject fixing material into the slot, then the injection process is simple, but the magnet can only be moved in one direction making it difficult to fix at an appropriate position
Solution Approach 1:
The single fixing-material-injection portion is divided into multiple fixing-material-injection portions (first injection portion and second injection portion) arranged at different locations around the slot. This segmentation allows the magnet to be pushed from multiple directions, enabling precise positioning at the center of the slot while maintaining a relatively simple injection process.
Solution Approach 2:
Each fixing-material-injection portion is equipped with independently controllable injection parameters (injection timing, injection speed, injection amount). This local quality control allows different regions of the slot to receive fixing material with different characteristics, enabling precise manipulation of magnet position and orientation during the injection process.
2Manufacturing precision
If multiple fixing-material-injection portions are used with different injection parameters, then the magnet can be fixed at any appropriate position, but the control complexity increases
Solution Approach 1:
The injection system transitions from static, simultaneous injection to dynamic, sequential injection. The control system dynamically adjusts injection timing, speed, and amount for each injection portion based on the desired magnet position. This dynamic control enables precise positioning while managing complexity through programmable sequences rather than complex mechanical arrangements.
Solution Approach 2:
The system incorporates feedback control where the injection parameters of subsequent portions are adjusted based on the position achieved by previous portions. This feedback mechanism allows the system to converge on the target position iteratively, reducing the need for highly complex open-loop control while achieving high positioning accuracy.
3Adaptability or versatility
If the injection timing and amount are made to differ among injection portions, then the magnet positioning flexibility is improved, but the process control difficulty increases
Solution Approach 1:
The control system pre-calculates and pre-sets the injection parameters (timing, speed, amount) for each fixing-material-injection portion based on the desired final magnet position. This preliminary action approach allows the complex multi-parameter control to be broken down into predetermined sequences, reducing real-time control difficulty while maintaining positioning flexibility.
Solution Approach 2:
The system utilizes parameter changes in the fixing material (temperature, viscosity, injection pressure) as controllable variables to achieve different positioning effects. By changing physical parameters of the fixing material during injection, the system can manipulate magnet position and orientation without requiring complex mechanical adjustments, simplifying the overall control process.
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
Enables the magnet to be fixed at any appropriate position, improving the repeatability and accuracy of the manufacturing process, reducing variations, and ensuring proper magnetic alignment and stress distribution within the rotor.
Implementation Method 1
injecting a fixing material into a space between an inner surface of the slot and the magnet from a plurality of fixing-material-injection portions opened to the space in the slot
Data Source
AI summary
A rotor manufacturing method, which is method for manufacturing a rotor that includes a rotor core and a magnet inserted into a slot formed in the rotor core, includes a magnet-insertion step of inserting the magnet into the slot; and a fixing-material-injection step of injecting a fixing material into a space between an inner surface of the slot and the magnet from a plurality of fixing-material-injection portions of the slot. In the fixing-material-injection step, a time for starting injection of the fixing material into the slot is made to differ among the plurality of fixing-material-injection portions.