Stator and Mold Preheating Using Coil Heat in a Covered Frame
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Solution Overview
Problem
Existing methods for preheating unfinished stators for motors are inefficient as they require lengthy heating times and complex facility structures, particularly due to the need to separately preheat molds and cores, leading to increased processing time and facility complexity.
Innovation Solution
A method involving a mold with a hollow barrel and flange portion, where the unfinished stator is preheated by conducting heat from AC-coiled coils through a heat-resistant box, uniformly heating the core, frame, and mold, simplifying the preheating process and reducing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a heater is provided to directly heat the outer peripheral portion of the core, then the preheating time is shortened, but the structure of preheating facilities becomes complicated
Solution Approach 1:
The coils serve dual purposes: as electromagnetic components of the motor and as heating elements for preheating the core and mold. By utilizing the coils' own resistive heating capability when alternative current is applied, the system eliminates the need for separate heating facilities, thereby reducing structural complexity while maintaining efficient preheating performance
2Device complexity
If the mold is excluded from preheating, then the preheating facilities structure is simplified, but the mold requires separate heating before molding which increases total processing time
Solution Approach 1:
The preheating process merges the heating of the unfinished stator (core and coils) with the heating of the mold into a single simultaneous operation. The heat-resistant box encloses both the stator and mold, allowing thermal energy from the coils to warm both components together, thereby eliminating separate heating steps and reducing total processing time
3Manufacturing precision
If electrical heating of the coils is used to heat the core uniformly, then the core is heated evenly, but it takes a lot of time
Solution Approach 1:
The heat-resistant box acts as an intermediary thermal environment that traps and circulates heat around both the unfinished stator and the mold. This enclosed space allows heat to distribute uniformly through convection and radiation, ensuring even heating of the core while significantly reducing the time required compared to direct electrical heating alone
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 efficiently preheats the inner and outer core, frame, and mold in a short time, simplifying the preheating facilities and improving efficiency by allowing the coils to reach a predetermined temperature quickly before cooling down to a suitable temperature for molding.
Implementation Method 1
turning on an alternative current to the coils in the heat-resistant box to cause the coils to generate heat
Implementation Method 2
preheating the core, the frame and the mold for molding by the heat which is conducted from the coils
Data Source
AI summary
A method of preheating an unfinished stator as an intermediate product before a stator as a final product for a motor is provided in order to preheat a mold for molding together with the unfinished stator in short time by using preheating facilities with simplified structures. In the method, the mold has a hollow and longitudinal barrel portion and a flange portion extending outward from an end of the barrel portion. The flange portion is arranged at a horizontal position to turn the barrel portion upward and an end of a cylindrical and longitudinal frame is put on the flange portion in a state where a core of the unfinished stator is fitted in the frame. A heat-resistant box of which an underside is opened covers the frame and the mold to surrounded outsides of the frame and the mold.