Rotor Manufacturing Device Sheet Magnet Insertion

Solution Overview

Problem

Existing methods for inserting permanent magnets and adhesive sheets into rotor slots of rotating electrical machines risk damaging the sheets due to the alignment and insertion process, particularly when using guide devices that require sheets to be inserted before the magnet.

Innovation Solution

A rotor manufacturing device with separate sheet guides and a holder that allows for the aligned insertion of sheets and permanent magnets into slots, featuring symmetrical sheet guides and retaining plates with equal spring constants to prevent damage and ensure accurate centering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If sheets are inserted into the slot prior to the permanent magnet using a guide device, then the insertion sequence is feasible, but the permanent magnet may tear or damage the sheet during alignment and insertion

Engineering Contradiction:

Improveinsertion sequence feasibilityVSAvoidsheet damage by permanent magnet

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The guide device is segmented into separate functional components: a guide hole for sheet insertion and a magnet outlet for permanent magnet insertion. The sheet guide feeds sheets into the slot through the guide hole, while the holder feeds the permanent magnet through the magnet outlet, which is positioned separately from the guide hole. This segmentation allows sheets and magnets to be inserted through different paths, preventing the magnet from contacting and damaging the sheet during insertion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The guide hole acts as an intermediary structure that receives sheets first and positions them in the slot before the permanent magnet is inserted. The separate magnet outlet serves as another intermediary path that allows the magnet to be inserted without contacting the sheet. These intermediary structures mediate the insertion process to prevent direct contact between the magnet and sheet during insertion.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If sheets are inserted after the permanent magnet, then the magnet is already in place, but it becomes impractical to insert flexible sheets into the narrow gap between the magnet and slot internal face

Engineering Contradiction:

Improvemagnet positioning stabilityVSAvoidsheet insertion difficulty

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The sheet guide is designed to feed sheets into the slot through the guide hole in advance, before the permanent magnet is inserted through the magnet outlet. This preliminary action of inserting sheets first creates the necessary positioning and spacing that allows subsequent magnet insertion without difficulty, and ensures the sheets are already in place to receive and secure the magnet.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If a single guide hole is used for both sheet and magnet insertion, then the device structure is simplified, but the magnet alignment process risks damaging the sheet

Engineering Contradiction:

Improveguide device structureVSAvoidsheet damage during alignment

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The guide device is segmented into separate functional components: a guide hole for sheet insertion and a magnet outlet for permanent magnet insertion. The sheet guide feeds sheets into the slot through the guide hole, while the holder feeds the permanent magnet through the magnet outlet, which is positioned separately from the guide hole. This segmentation allows sheets and magnets to be inserted through different paths, preventing the magnet from contacting and damaging the sheet during insertion.

Inventive Principle:

Principle #1Segmentation

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 safe and precise insertion of sheets and permanent magnets into rotor slots without damaging the sheets, ensuring proper alignment and fixation while preventing sheet contact with the magnet during insertion.

Implementation Method 1

The pair of retaining plates are made to have equal spring constants. The retaining plates may bend away from the axis of symmetry while the permanent magnet is inserted into the slot

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11637486B2Rotor manufacturing device

Publication Date: 2023.04.25 TOYOTA JIDOSHA KK

AI summary

A guide device which is a rotor manufacturing device includes a pair of sheet guides and a holder. The holder is disposed between the pair of sheet guides and includes a magnet outlet through which a permanent magnet is inserted into the slot from above. The pair of sheet guides is linearly symmetrical in a front view in which a side of the pair of sheet guides is located at the front. The axis of symmetry of the pair of sheet guides and the center axis of the magnet outlet are aligned with each other in the front view.