Shrink-Fitting Laminated Rotor Using Alignment Jig
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Solution Overview
Problem
The existing shrink-fitting method for laminated rotors faces challenges with misalignment between the ring and the laminated rotor core, leading to difficulties in inserting the rotor shaft and potential scratches on the inner peripheral surface, due to differences in outer diameters and the complexity of center alignment.
Innovation Solution
A simply-configured ring attachment jig with projections is used to align the center of the ring with the laminated rotor core, allowing for accurate positioning and reducing misalignment by fitting the projections into attachment holes, and the ring is heated and pressed against the core to facilitate smooth insertion and secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ring is disposed at an axial end of the laminated rotor core to prevent contact portion bending, then the reliability of the shrink-fitting process is improved, but the device complexity increases due to the need for additional positioning mechanisms to align the ring center with the rotor core center
Solution Approach 1:
The positioning function is segmented into two independent parts: the ring attachment jig with projections for positioning the ring, and the rotor core with corresponding attachment holes. This segmentation allows each component to be manufactured and positioned independently, reducing overall system complexity while maintaining alignment accuracy.
Solution Approach 2:
The ring attachment jig acts as an intermediary component between the ring and the rotor core. It provides a simple positioning mechanism through projections that fit into attachment holes, serving as a mediator that enables accurate alignment without requiring complex positioning systems.
2Productivity
If the ring and laminated rotor core are heated together for shrink-fitting, then the productivity of the manufacturing process is improved, but the energy consumption increases due to heating two separate components
Solution Approach 1:
The heating operations for the ring and the laminated rotor core are merged into a single simultaneous heating process. Both components are heated together in the same heating zone, which improves manufacturing efficiency by reducing the number of heating cycles while the energy consumption is optimized through coordinated heating timing.
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 method effectively reduces misalignment and prevents buckling of the laminated rotor core during insertion, ensuring a secure and accurate fastening of the rotor shaft, while also reducing heating and conveyance costs by shared heating of the ring and rotor core.
Implementation Method 1
after the ring and the laminated rotor core are heated
Implementation Method 2
shrink-fitting method for a laminated rotor, a shrink-fitting method being a method for fitting a laminated rotor core onto a rotor shaft by shrink-fitting
Data Source
AI summary
A shrink-fitting method for a laminated rotor includes: disposing, coaxially with a laminated rotor core, an annular ring having a through-hole, at an axial end of the laminated rotor core including laminated annular steel sheets and having a through-hole extending in its axial direction; and inserting a rotor shaft into the through-holes of the ring and the laminated rotor core after heating them. A ring attachment jig having a circular internal space, where the ring is disposed, has projections projecting from an axial end surface thereof in the axial direction and arranged along a circumferential direction of the circular internal space. The center of the ring is aligned with the center of the laminated rotor core, by fitting the projections in attachment holes axially extending in the laminated rotor core, and fitting the ring to an inner peripheral surface of the ring attachment jig, which defines the circular internal space.