Rotor Stack Assembly With Force Feedback for Variable Core Sizes
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Solution Overview
Problem
The assembly of electric motor rotors with varying sizes and magnet configurations poses challenges due to complex and inflexible manufacturing processes, particularly in accommodating different size rotor cores and magnetizable inserts, which hinders dynamic and flexible configurations.
Innovation Solution
A method employing force control feedback robotic systems to precisely place rotor cores on a mandrel and insert magnetizable inserts into cavities, using multi-axial industrial robotic arms with end-of-arm tools and load cells for accurate positioning and alignment, allowing for adaptability in assembly processes and tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional rigid assembly lines are used to assemble rotor cores with varying sizes and magnet configurations, then manufacturing process stability is maintained, but adaptability to different platform requirements deteriorates
Solution Approach 1:
The assembly system transitions from rigid fixed-position stations to dynamic robotic arms with multi-axis movement capabilities. The robotic system can dynamically adjust positions, orientations, and speeds to accommodate different rotor core sizes and magnet configurations, enabling flexible reconfiguration without physical line changes.
Solution Approach 2:
A single robotic assembly system performs multiple functions: positioning rotor cores, placing magnetizable inserts, and adapting to various platform requirements. The force control feedback mechanism provides universal applicability across different assembly tasks and configurations.
2Manufacturing precision
If force control feedback robotic systems are employed to precisely place rotor cores and magnetizable inserts, then manufacturing precision is improved, but system complexity increases
Solution Approach 1:
Force control feedback is integrated into the robotic end-effectors to provide real-time force monitoring and adjustment during magnetizable insert placement. This feedback mechanism enables precise control of insertion forces, ensuring accurate positioning while accommodating variations in cavity dimensions and insert geometries.
Solution Approach 2:
Traditional mechanical positioning and alignment mechanisms are replaced with robotic arms equipped with force control and multi-axis movement. This substitution reduces the need for complex mechanical fixtures and alignment devices while achieving superior placement precision through software-controlled dynamics.
3Productivity
If multiple insert assembly robots are used to place magnetizable inserts into multiple cavities simultaneously, then productivity is improved, but device complexity increases
Solution Approach 1:
Multiple insert placement operations are merged into a single coordinated robotic system. The robotic arm performs sequential placement of magnetizable inserts into multiple cavities through rapid repositioning, eliminating the need for multiple independent robots while maintaining high assembly throughput.
Solution Approach 2:
The robotic assembly process maintains continuous productive action by minimizing idle time between insert placements. The force control feedback enables rapid insertion and release cycles, keeping the robotic system continuously engaged in value-added assembly operations without requiring complex multi-robot coordination.
Data Source
AI summary
The present disclosure is generally directed toward a method of assembling a plurality of rotor cores for an electric converter. The method includes placing, by a core robotic system employing force control feedback, a rotor core on a mandrel, and for each of the plurality of rotor cores, placing, a plurality of magnetizable inserts into a plurality of cavities in the rotor core by an insert assembly robotic (IAR) system employing force control feedback.