Vibrating Motor Rotor Integral Molding Coaxial Accuracy
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Solution Overview
Problem
Conventional production methods for vibrating motors require many steps and result in low coaxial accuracy due to the need for adhesive fixation of the shaft to the eccentric weight, leading to increased production costs and complexity.
Innovation Solution
The rotor is integrally formed using thermoplastic magnetic material, where the shaft, eccentric weight, and permanent magnet are molded together, eliminating the need for adhesives and reducing production steps while ensuring high coaxial accuracy through precise positioning and material compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shaft is fixed to the eccentric weight by adhesives, then the assembly is simple to manufacture, but the coaxial accuracy is limited due to the necessary clearance for adhesives
Solution Approach 1:
The shaft and eccentric weight are merged into a single integrally formed component through injection molding, eliminating the need for adhesive fixation and the associated clearance requirements. This combining of previously separate parts resolves the contradiction by achieving both manufacturing simplicity and high coaxial accuracy simultaneously.
Solution Approach 2:
The mechanical adhesive fixation system is replaced with a direct integral formation process using injection molding. This substitution eliminates the clearance necessary for adhesive application and curing, thereby achieving high coaxial accuracy while maintaining ease of manufacture through the molding process.
2Reliability
If conventional production methods with multiple steps are used, then the manufacturing process is well-established, but the production costs are increased and the process complexity is high
Solution Approach 1:
Multiple separate manufacturing steps (shaft fabrication, eccentric weight fabrication, adhesive bonding, alignment) are merged into a single injection molding process. This integration reduces production process complexity while maintaining reliability through the established molding technology.
Solution Approach 2:
The rotor is divided into functional regions (shaft portion, eccentric weight portion, permanent magnet portion) that are all formed in one molding process. This segmentation within integration allows for optimized design of each functional area while simplifying the overall manufacturing process.
3Ease of operation
If adhesives are used to fix the shaft to the eccentric weight, then the assembly process is simple, but surplus clearances are required which reduce accuracy
Solution Approach 1:
The shaft and eccentric weight are combined into a single integrally formed component, eliminating the need for adhesive assembly operations. This merger removes the surplus clearances required for adhesive application while maintaining operational simplicity through the one-step molding process.
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 approach simplifies the production process, enhances coaxial accuracy, and reduces costs by eliminating the need for adhesives and surplus clearances, resulting in a more efficient and accurate vibrating motor assembly.
Implementation Method 1
injecting the thermoplastic magnetic material composing a permanent magnet into the mold
Data Source
AI summary
A vibrating motor has a shaft, a stator including a yoke having pole teeth extending toward an axis of the shaft from an inner circumference and coils wound around the pole teeth, a rotor including an eccentric weight formed on a radially outer surface of the shaft, and a permanent magnet integrally formed with the eccentric weight, and a bearing device rotatably supporting the rotor maintaining clearance between the inner circumference of the pole teeth and the rotor. The rotor has a structure in which the shaft, the eccentric weight, and the permanent magnet are integrally formed with each other by a thermoplastic magnetic material composing the permanent magnet.