Stacked Motor Core Resin Injection Control via ID Code
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Solution Overview
Problem
Existing manufacturing methods for stacked cores lack precision in resin filling, as they do not account for variations in stack type and configuration, leading to inefficiencies and potential defects in motor core production.
Innovation Solution
A manufacturing method and device that utilize an information storage portion on electrical steel sheets to determine the type of resin material, injection amount, and discharge position, allowing for controlled resin filling based on read information, ensuring accurate and efficient resin injection into the motor core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed resin filling method is used for all stacks, then the manufacturing process is simple, but the manufacturing precision deteriorates due to inability to account for stack type variations
Solution Approach 1:
The patent implements dynamic adaptability by enabling the resin filling device to adjust its operating parameters (resin type, injection amount, discharge position) based on the specific stack type being processed. The system transitions from a fixed, static configuration to a dynamic one that can be reconfigured for different stack variants through information storage portions and control module adjustments.
Solution Approach 2:
The patent changes key process parameters (resin material type, injection amount, discharge position) according to the stack type. The control module modifies these parameters based on information read from the information storage portion, allowing the same physical device to achieve precise resin filling for multiple stack configurations without physical reconfiguration.
2Manufacturing precision
If generic resin filling is applied to all stacks, then the device operation is simple, but the manufacturing precision deteriorates
Solution Approach 1:
The system performs self-configuration by automatically reading stack type information from the information storage portion and autonomously setting the appropriate resin filling parameters. The control module executes this self-service function without requiring manual intervention or complex operator decisions, maintaining ease of operation while achieving precision.
Solution Approach 2:
The patent implements a feedback mechanism where the control module reads information from the information storage portion about the stack type and uses this feedback to automatically adjust the resin filling parameters. This closed-loop information flow enables precise operation without increasing operational complexity, as the system self-regulates based on received information.
3Productivity
If mold conditions are manually adjusted for each stack type, then the resin filling precision is high, but the productivity deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-storing stack type information in information storage portions attached to each stack before the resin filling process. The control module reads this pre-provided information and automatically configures the appropriate mold conditions, eliminating the need for manual adjustment and thereby maintaining high productivity while ensuring precision.
Solution Approach 2:
The patent replaces manual mechanical adjustment of mold conditions with an automated information-based control system. Instead of physically changing components or manually setting parameters for each stack type, the system uses information reading and electronic control to automatically configure the resin filling process, significantly improving manufacturing efficiency without sacrificing precision.
Data Source
AI summary
The manufacturing method of a motor core includes attaching an ID code to a stack of blanked members in which a magnet insertion hole to fill with a resin material is formed, the ID code containing information in accordance with a type of the stack, reading the information from the ID code which is attached to the stack, and setting a mold condition based on the information read from the ID code. The mold condition includes at least one type of condition including: the resin material to be injected to the magnet insertion hole, an injection amount of the resin material, and a discharge position of the resin material. A mold device is controlled to inject the resin material to the magnet insertion hole in accordance with the mold condition.