Rotor Resin Runner Layout for Flexible Magnet Hole Injection
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Solution Overview
Problem
The challenge of manufacturing rotors for rotary electric machines with varying magnet hole positions using a single resin injector, which leads to increased costs due to the need for frequent changes in the resin injection apparatus.
Innovation Solution
A rotor manufacturing apparatus and method that utilizes a resin injector with a runner system, allowing for the same injector to be used across different rotor shapes by replacing the runner to match the specific hole positions, eliminating the need for changing the resin injector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the resin injector is changed to handle different rotor shapes with varying hole positions, then the manufacturing flexibility is improved, but the device complexity and cost increase
Solution Approach 1:
The resin injection system is divided into two independent parts: a universal resin injector and a shape-specific runner. The runner is segmented to match specific rotor hole positions, while the resin injector remains standardized. This segmentation allows the resin injector to handle different rotor shapes by simply changing the runner component, thereby improving manufacturing flexibility without increasing the complexity of the main resin injector.
Solution Approach 2:
The resin injector is designed with universal functionality to work with multiple rotor shapes. By making the resin injector multi-functional and pairing it with interchangeable runners, the system achieves adaptability across different product configurations without requiring multiple specialized injectors, thus reducing device complexity and cost.
2Manufacturing precision
If the resin injector is changed frequently to accommodate different rotor shapes, then the manufacturing precision is maintained, but the productivity decreases
Solution Approach 1:
By segmenting the injection system into a universal resin injector and interchangeable runners, the patent enables quick changeovers between different rotor shapes. The runner can be rapidly swapped to match specific hole positions, maintaining manufacturing precision while minimizing downtime and improving overall productivity.
3Manufacturing precision
If the resin injector is changed to match different hole positions, then the manufacturing precision is improved, but the loss of time increases
Solution Approach 1:
The segmentation of the injection system allows only the runner component to be changed rather than the entire resin injector. This reduces the changeover time significantly while maintaining the precision required for different hole positions, as the standardized resin injector can quickly accommodate the new runner configuration.
Solution Approach 2:
Runners are pre-configured to match specific rotor shapes and hole positions. This preliminary preparation allows for rapid changeovers without requiring time-consuming adjustments or modifications during the manufacturing process, thereby reducing time loss while maintaining manufacturing precision.
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 cost-effective production of rotors with diverse hole positions by using a single resin injector, reducing operational costs and improving manufacturing flexibility.
Implementation Method 1
a resin injector having a first ejection port for ejecting a resin
Implementation Method 2
heating the thermosetting resin, thereby obtaining a rotor having the magnets embedded in the rotor core
Data Source
AI summary
A resin injection apparatus configured to manufacture a rotor of a rotary electric machine includes a resin injector having an ejection port for ejecting a resin, and a runner having a charging port connectable to the ejection port, and a plurality of ejection ports communicating with the charging port and disposed at positions associated with hole portions of a rotor core where magnets are disposed.