Rotational Electric Machine Rotor Swaging Fixation
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Solution Overview
Problem
The assembly of rotational electric machine rotors requires a complex and costly process due to the need for precise fixation of rotor shafts and cores, especially when using stacked magnetic body thin plates, which increases fabrication costs and assembly time.
Innovation Solution
A method involving a rotor shaft with a non-circular sectional shape and a rotor core with corresponding non-circular center holes, where the rotor shaft is expanded outward to form a protruding part for fixation, eliminating the need for screw fastening and stack swaging processing, thereby simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screw fastening and rotation prevention mechanisms are used to fix the rotor shaft and rotor core, then reliable fixation is achieved, but the device complexity and fabrication cost increase
Solution Approach 1:
The patent combines multiple fixation functions (axial positioning, rotation prevention, and mechanical bonding) into a single integrated swaging structure. The swaging part on the rotor shaft performs both axial fixation and circumferential locking through plastic deformation, eliminating the need for separate screws, nuts, and key-way mechanisms.
Solution Approach 2:
The swaging structure creates its own fixation mechanism through plastic deformation of the rotor shaft material. The material itself serves as the bonding agent, forming protrusions that mechanically interlock with the rotor core without requiring external fasteners or additional bonding materials.
2Reliability
If conventional screw fastening and rotation prevention mechanisms are used to fix the rotor shaft and rotor core, then reliable fixation is achieved, but the fabrication cost increases
Solution Approach 1:
The patent extracts and eliminates unnecessary components (screws, nuts, washers, key-ways) from the assembly, retaining only the essential swaging structure. This reduction in component count directly lowers material costs, assembly time, and manufacturing complexity while maintaining fixation reliability.
Solution Approach 2:
The invention changes the physical state of the rotor shaft material through plastic deformation during swaging. This parameter change transforms the material from a rigid cylindrical form to a shaped structure with protrusions that provide mechanical interlocking, eliminating the need for threaded fasteners and reducing fabrication costs.
3Manufacturing precision
If the rotor core is made of stacked magnetic body thin plates requiring precise fixation, then assembly precision is improved, but the assembly time and processing cost increase
Solution Approach 1:
The swaging structure is formed in advance during rotor shaft manufacturing, creating pre-positioned fixation features. When the rotor core is assembled, these pre-formed swaging protrusions immediately provide alignment and fixation, eliminating the need for time-consuming adjustment and bonding operations on stacked magnetic plates.
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 reduces the cost of assembling rotor cores and shafts by eliminating the need for complex screw fastening and stack swaging, while ensuring secure fixation without additional rotation prevention mechanisms.
Implementation Method 1
squashing the rotor shaft extending out of an axial-direction end face of the rotor core by using a predetermined swaging jig to expand the rotor shaft outward
Data Source
AI summary
A method of manufacturing a rotational electric machine rotor includes: forming a rotor shaft having a non-circular sectional outer shape; forming a rotor core by stacking a predetermined number of magnetic body thin plates each including a center hole having a non-circular shape corresponding to the non-circular sectional outer shape of the rotor shaft; and forming a protruding part for fixing the rotor core and the rotor shaft to each other by inserting the rotor shaft into the non-circular center hole of the rotor core and squashing the rotor shaft extending out of an axial-direction end face of the rotor core by using a predetermined swaging jig to expand the rotor shaft outward beyond an outer periphery of the non-circular section along the axial-direction end face of the rotor core.