Induction Motor Rotor Vertical Casting to Eliminate Porosity
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Solution Overview
Problem
Existing methods for manufacturing induction motor rotors using horizontal die casting result in defects such as bubble formation, heat generation, noise, vibration, and efficiency degradation due to gravitational effects and contraction deformation, leading to reduced motor efficiency.
Innovation Solution
A vertical pressing method is employed using an upper mold, lower mold, sleeve, plunger, and squeeze pins to inject molten metal into the rotor assembly, applying pressure in a longitudinal direction to achieve zero porosity and prevent contraction and deformation, with additional support from slide cores and controlled temperature preheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If horizontal die casting method is used, then production cost is low and mold structure is simple, but bubble defects are concentrated due to gravitational effects
Solution Approach 1:
The patent inverts the conventional horizontal die casting orientation to vertical die casting. By changing the casting direction from horizontal to vertical, the molten metal flows downward under gravity, allowing bubbles to rise to the top rather than concentrating in the product. This inversion of the casting orientation resolves the contradiction by maintaining simple mold structure while eliminating gravitational defects.
Solution Approach 2:
The patent transitions from horizontal casting to vertical casting, changing the spatial dimension of the casting process. This dimensional change alters the direction of gravitational force relative to the mold cavity, enabling bubbles to escape in the vertical direction while the mold structure remains relatively simple.
2Ease of manufacture
If horizontal die casting is used, then production cost is low, but contraction and deformation of electrical steel sheet occur after solidification
Solution Approach 1:
By inverting the casting orientation from horizontal to vertical, the patent enables the core to remain stable during solidification. The vertical orientation allows for better support and restraint of the electrical steel sheet core, preventing contraction and deformation while maintaining cost-effectiveness.
3Device complexity
If molten metal is cast horizontally, then production process is simple, but porosity occurs in the product
Solution Approach 1:
The patent applies the inversion principle by changing the casting direction from horizontal to vertical. This simple orientation change causes bubbles to rise to the top of the mold cavity during vertical casting, eliminating porosity in the product while keeping the casting process itself simple and not requiring complex additional equipment.
4Manufacturing precision
If vertical pressing method is used to achieve zero porosity, then product quality improves, but device complexity increases
Solution Approach 1:
The patent achieves high product quality through the inversion of casting orientation to vertical, which naturally eliminates porosity by allowing bubbles to rise. The device complexity is minimized by using a straightforward vertical mold structure without requiring complex additional mechanisms, achieving quality improvement with relatively simple device design.
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
The method ensures zero porosity and minimizes defects, enhancing motor efficiency by reducing oxygen and hydrogen saturation, shortening casting cycles, and maintaining core temperature, thereby improving rotor quality.
Implementation Method 1
the rotor assembly is pressurized in a vertical direction and an outer peripheral surface of a core of the rotor assembly is filled with the molten metal in a longitudinal direction
Implementation Method 2
contraction occurs after the aluminum molten metal solidifies
Implementation Method 3
contraction occurs after the aluminum molten metal solidifies, causing a problem of contraction and deformation of the electrical steel sheet
Implementation Method 4
a pair of slide cores disposed to face each other in a lateral direction based on the rotor assembly and configured to support a side surface of the rotor assembly
Data Source
AI summary
A device for manufacturing a rotor for an induction motor includes an upper mold formed at a center of a bottom surface of a base portion, a lower mold formed in a center of an upper surface of the base portion, a sleeve formed on an inner surface of the lower mold, a biscuit which is formed inside the sleeve and into which a molten metal is injected, and a plunger disposed inside the sleeve, wherein the rotor assembly is pressurized in a vertical direction and an outer peripheral surface of a core of the rotor assembly is filled with the molten metal to manufacture a rotor. According to the present disclosure, it is possible to cast the rotor in a vertical manner and pressurize both ends of the rotor to achieve zero porosity and prevent contraction and deformation of the core.