Winding Field Rotor Varnish Coating Through Rotational Immersion
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Solution Overview
Problem
Existing methods for coating the entirety of coil surfaces in winding field rotors with varnish are complicated due to air accumulation between coils, making it difficult to achieve uniform varnish coating.
Innovation Solution
A method and device for manufacturing a winding field rotor that uses a rotor assembly with prescribed end rings, where the coil end part on one axial-end side is immersed in varnish while the rotor assembly is rotated, allowing for complete varnish coating without complex operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coils are coated with varnish through immersion, then the coil surfaces can be coated with varnish, but air accumulates between the coils making it difficult to coat the entirety of coil surfaces including coil surfaces between the coils
Solution Approach 1:
The end rings are designed with flange parts that protrude radially inward before the varnishing process, creating a predetermined air escape path structure. This preliminary structural arrangement enables air to escape during immersion without requiring complex operational adjustments, allowing complete varnish coating between coils while maintaining simple operations
Solution Approach 2:
The flange parts of the end rings act as intermediaries that facilitate air escape during varnish immersion. These protruding structures create channels that guide air away from the coil ends, enabling complete varnish penetration between coils without requiring complicated tilting or positioning operations
2Manufacturing precision
If the winding field rotor is tilted to facilitate air escape during varnishing, then air can escape more readily, but the operation becomes complicated
Solution Approach 1:
The air escape paths are built into the rotor assembly structure through flange parts before the varnishing process begins. This preliminary structural preparation eliminates the need for complicated tilting operations, as air can escape through the predetermined paths regardless of the rotor's orientation during immersion
Solution Approach 2:
Instead of tilting the rotor to create air escape paths, the invention inverts the approach by creating fixed air escape paths within the rotor structure itself. The flange parts protruding radially inward provide built-in channels that guide air escape without requiring external operational adjustments
3Manufacturing precision
If varnish is supplied through a gap between the rotor shaft and flange part while the rotor assembly rotates, then the entirety of coil surfaces can be coated with varnish, but the device requires rotation mechanism
Solution Approach 1:
The invention employs dynamic rotation of the rotor assembly during varnish immersion, allowing the coils to rotate through the varnish material. This rotational motion ensures complete coating of all coil surfaces including those between coils, while the simple immersion setup keeps the overall device complexity low
Solution Approach 2:
The varnish is supplied as a liquid material through a gap, utilizing fluid dynamics to penetrate between the rotating coils. The liquid varnish flows along with the rotating coils, ensuring complete coverage without requiring complex application mechanisms
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 the complete varnish coating of coil surfaces in winding field rotors, improving the reliability and durability of the rotor and simplifying the manufacturing process.
Implementation Method 1
the rotor assembly is caused to rotate about an axis
Implementation Method 2
a varnish material is supplied through a gap between the rotor shaft and the flange part on one axial-end side to immerse, in the varnish material, the coil end part
Data Source
AI summary
A manufacturing method and a manufacturing device for manufacturing a winding field rotor in which it is possible to coat the entirety of coil surfaces with varnish, without requiring a complicated operation or action. The manufacturing method for a wound-field rotor involves supplying a varnish material through a gap between the rotor shaft and the flange part on one axial-end side to immerse the coil end part on the one axial-end side at a lower side of the rotor assembly in the varnish material, while rotating the rotor assembly whose axial direction is aligned horizontally.