Rotor Sheet Tensioning for Magnet Insertion
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Solution Overview
Problem
Existing manufacturing methods for electric motor rotors with through holes risk damaging sheets when inserting magnets due to the narrow space and potential tearing, especially in tight spaces.
Innovation Solution
The method involves inserting a sheet into the through hole before the magnet, applying tension to the sheet by pulling it from both ends to smooth its surface, allowing the magnet to slide in smoothly and reducing the likelihood of sheet damage during insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sheet is used to fix a magnet in a through hole, then the magnet can be secured in place, but the sheet may be torn during insertion due to the narrow space
Solution Approach 1:
The sheet is inserted into the through hole before the magnet is inserted. This preliminary action allows the sheet to be properly positioned and smoothed against the inner surface before the magnet insertion process begins, preventing the magnet from directly contacting and potentially tearing the sheet during insertion.
Solution Approach 2:
The insertion process is divided into separate steps: first inserting the sheet, then inserting the magnet. This segmentation of the insertion process allows each component to be properly positioned without interfering with the other, reducing the risk of sheet damage.
2Manufacturing precision
If tension is applied to the sheet by pulling from both ends, then the sheet surface becomes smooth for magnet insertion, but additional force is required
Solution Approach 1:
Tension is applied to the sheet in advance before magnet insertion to smooth its surface. This preliminary smoothing action ensures that the sheet surface is properly prepared for the subsequent magnet insertion, reducing friction and the risk of sheet damage during the actual magnet insertion process.
3Power
If the space between the inner surface of the through hole and the magnet is reduced, then magnetic flux generation is enhanced, but the sheet is more likely to be torn during magnet insertion
Solution Approach 1:
The sheet is inserted and smoothed against the inner surface before the magnet is inserted. This preliminary positioning ensures that when the magnet is inserted close to the inner surface for optimal magnetic flux generation, the sheet is already properly positioned and less likely to be torn during the insertion process.
Solution Approach 2:
The insertion process is separated into distinct steps: sheet insertion followed by magnet insertion. This segmentation allows the sheet to be properly positioned first, creating a protective barrier that enables the magnet to be inserted close to the inner surface without directly contacting and potentially tearing the sheet.
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 approach minimizes sheet damage and allows for closer magnet placement, enhancing magnetic flux generation and reducing iron loss by preventing electrical conduction and allowing for effective cooling.
Implementation Method 1
The sheet is stretched in an axial direction of the rotor core by the application of tension, which makes a surface of the sheet smooth
Implementation Method 2
The magnet slides smoothly on the surface of the sheet to be inserted through the through hole
Implementation Method 3
preventing electrical conduction and allowing for effective cooling
Data Source
AI summary
A manufacturing method of a rotor for an electric motor is disclosed herein. The rotor may include a rotor core having a through hole that extends along an axial direction of the rotor; a magnet inserted in the through hole; and a sheet disposed between an inner surface of the through hole and the magnet. The method may include inserting the sheet into the through hole such that the sheet extends through the through hole; and inserting the magnet into the through hole while the sheet is pulled at axial ends of the sheet in opposite directions to apply tension to the sheet and press the sheet against the inner surface.