Rotor Stack Assembly With Force Feedback for Size Variations
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Solution Overview
Problem
The assembly of rotor stacks for electric motors is complex due to variations in size and magnet type across different platforms, leading to rigid and inflexible assembly lines that hinder dynamic configurations.
Innovation Solution
A method and system utilizing force control feedback robotic systems to precisely position and assemble rotor cores and magnetizable inserts, allowing for flexible configurations and adaptability to different sizes and tolerances through core and insert assembly robotic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional rigid assembly lines are used to assemble rotor stacks, then assembly process stability is maintained, but adaptability to different size configurations and magnet types deteriorates
Solution Approach 1:
The patent employs dynamic robotic systems with force control feedback that can adapt their positioning and assembly operations in real-time based on detected variations in rotor core dimensions and cavity positions. This enables the assembly line to handle different size configurations without requiring rigid reconfiguration, directly resolving the contradiction between adaptability and device complexity.
Solution Approach 2:
The system changes operational parameters dynamically through force control feedback, adjusting positioning forces and alignment parameters based on detected variations in each rotor core. This allows the same assembly equipment to accommodate different size configurations by modifying control parameters rather than physical equipment configuration.
2Manufacturing precision
If force control feedback robotic systems are implemented for precise positioning, then manufacturing precision is improved, but system complexity increases
Solution Approach 1:
The patent implements force control feedback systems that continuously monitor contact forces during positioning operations and automatically adjust robotic movements to achieve precise alignment of rotor cores and magnetizable inserts. This feedback mechanism enables high manufacturing precision while using standardized robotic equipment, managing the complexity through intelligent control rather than mechanical complexity.
3Adaptability or versatility
If multiple rotor cores with varying tolerances are assembled, then product versatility is improved, but assembly difficulty increases
Solution Approach 1:
The force control feedback system enables the robotic assembly equipment to automatically compensate for tolerance variations in each rotor core by sensing contact forces and self-adjusting positioning parameters. This self-service capability allows the system to handle varying tolerances across different rotor cores without requiring manual intervention or complex setup procedures.
Data Source
AI summary
The present disclosure includes a method of assembling a plurality of rotor cores for an electric converter. The method includes providing a core robotic system employing force control feedback and an insert assembly robotic (IAR) system; placing a rotor core of the plurality of rotor cores on a mandrel by the core robotic system employing force control feedback, wherein each rotor core from the plurality of rotor cores includes a plurality of cavities; and placing a plurality of magnetizable inserts into the plurality of cavities in the rotor core by the insert assembly robotic (IAR) system employing force control feedback.