Skew Rotor Core Module Assembly Without Keyed Shaft Alignment
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Solution Overview
Problem
The existing methods for assembling a rotor core with a skew structure for drive motors are complex and costly, requiring multiple manufacturing processes and increased facility investment due to the need for key processing and precise alignment of rotor core modules and permanent magnets.
Innovation Solution
An automated apparatus that assigns skew angles to rotor core modules and press-fits them onto a shaft, using a frame with a shaft fixing unit, elevation plate, core gripper, vision sensor, core rotating unit, and press-fitting unit, allowing for precise alignment and assembly without a key structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a key structure is used to apply skew angle to rotor core modules, then the rotor core can be assembled with precise angular positioning, but the number of manufacturing processes increases and facility investment cost increases
Solution Approach 1:
The patent removes the key structure from the rotor core modules, extracting the problematic element that caused increased manufacturing complexity. Instead of processing keys on multiple rotor core modules and key grooves on the shaft, the invention uses a simpler pressing structure that directly positions and secures the rotor core modules without requiring key processing operations.
Solution Approach 2:
The patent divides the rotor core into multiple independent rotor core modules that can be assembled separately and then combined on the shaft. Each module can be manufactured and positioned independently, allowing for simplified processing of individual components rather than requiring complex key processing on integrated structures.
2Manufacturing precision
If a key structure is used for skew angle application, then rotor core modules can be precisely positioned, but the design complexity increases and assembly difficulty increases
Solution Approach 1:
The key structure is completely removed from the design. The patent replaces the complex key-and-groove positioning mechanism with a simpler pressing and fitting structure that achieves the same positioning function through direct mechanical contact and friction, eliminating the need for precise key alignment and reducing assembly steps.
3Shape
If key processing is performed on rotor core modules and shaft, then skew structure can be applied, but facility investment cost increases
Solution Approach 1:
The patent eliminates the need for key processing facilities by removing the key structure entirely. The skew structure is achieved through the geometric design of the rotor core modules and shaft interface, allowing for standard pressing and fitting operations instead of requiring specialized key cutting and grooving equipment.
4Shape
If phase difference between key and permanent magnet insertion hole is considered, then rotor core can be designed with skew structure, but design complexity increases
Solution Approach 1:
The key structure that caused phase difference considerations is removed. The patent achieves the skew structure through the arrangement and geometry of the rotor core modules themselves, eliminating the need to coordinate key positions with permanent magnet insertion holes and reducing design complexity.
Data Source
AI summary
An apparatus for assembling a rotor for a drive motor is configured to press-fit, to a shaft, a plurality of rotor core modules, each of which has a plurality of stacked electrical steel sheets. The rotor may include a frame, a shaft fixing unit installed to the frame to fix the shaft along a vertical direction, an elevation plate having a through-hole formed to allow the shaft and the plurality of rotor core modules to pass therethrough along the vertical direction, and installed to the frame to be movable in the vertical direction, a core gripper, a main vision sensor, a core rotating unit connected to the core gripper, and a core press-fitting unit installed to the frame to press-fit the at least one rotor core module to the shaft along an axial direction.