Method and system for assembling a rotor stack for an electric motor

1 . A method for assembling a plurality of rotor cores of an electric converter by a central robotic system, the method comprising:

providing the central robotic system that includes a core controller, an insert assembly robotic (IAR) system that includes an IAR controller, and a central controller;

placing a rotor core of the plurality of rotor cores on a mandrel by the central robotic system, wherein the rotor core further comprises a plurality of cavities;

employing a first force control feedback from the core controller of the central robotic system to the central controller and the IAR controller;

placing a plurality of magnetizable inserts into the plurality of cavities in the rotor core by the IAR system; and

adjusting a movement of a robotic arm of the central robotic system based on the first force control feedback so that a detected force coincides with a defined value or profile.

2 . The method of claim 1 , wherein the plurality of magnetizable inserts includes a first set of magnetizable inserts and a second set of magnetizable inserts, wherein the first set of magnetizable inserts is of a different size than that of the second set of magnetizable inserts.

3 . The method of claim 1 , wherein placing the rotor core on the mandrel further comprises:

aligning an alignment feature at an inner diameter of the rotor core with an alignment feature at an outer diameter of the mandrel based on the first force control feedback detected by the core controller of the central robotic system; and

translationally moving the rotor core along the mandrel based on the first force control feedback detected by the core robotic system.

4 . The method of claim 1 further comprising:

transferring the plurality of rotor cores with the mandrel in response to completion of an assembly; and

placing a second mandrel for subsequent assembly of a second plurality of rotor cores by the core robotic system.

5 . The method of claim 1 further comprising:

monitoring the first force control feedback from the core controller of the central robotic system to the central controller; and

determining an abnormal installation operation in response to the monitored first force control feedback exceeding a desired parameter.

6 . The method of claim 1 , wherein the employing the first force control feedback from the core controller of the central robotic system to the central controller and the IAR controller further comprises:

detecting a force or torque, by the core robotic system; and

outputting the detected force or torque as an electrical signal.

7 . The method of claim 6 further comprising:

analyzing the electrical signal to determine whether the detected force or torque aligns with a defined value or profile; and

adjusting the movement of the robotic arm of the core robotic system until the detected force or torque values coincides with the defined value or profile by a controller of the core robotic system.

8 . The method of claim 6 further comprising:

detecting a force or torque by a second force control feedback of the IAR system;

outputting the detected force or torque as an electrical signal;

analyzing the electrical signal to determine whether the detected force or torque aligns with a defined value or profile; and

adjusting the movement of the insert assembly robot of the IAR system until the detected force or torque values coincides with the defined value or profile by a controller of the IAR system.

9 . A method for assembling a plurality of rotor cores of an electric converter by a central robotic system, the method comprising:

providing the central robotic system that includes a core controller, an insert assembly robotic (IAR) system that includes an IAR controller, and a central controller;

placing a rotor core of the plurality of rotor cores on a mandrel by the central robotic system, wherein the rotor core further comprises a plurality of cavities;

employing a first force control feedback from the core controller of the central robotic system to the central controller and the IAR controller;

placing a plurality of magnetizable inserts into the plurality of cavities in the rotor core by the IAR system by gripping, at a first orientation, one or more magnetizable inserts from the plurality of magnetizable inserts by a robotic arm of the IAR system; and aligning and positioning, at a second orientation different from the first orientation, the one or more magnetizable inserts at one or more cavities among the plurality of cavities based on a second force control feedback detected by the IAR controller of the IAR system; and

adjusting a movement of the robotic arm of the central robotic system based on the first force control feedback so that a detected force coincides with a defined value or profile.

10 . The method of claim 9 , wherein the placing the plurality of magnetizable inserts into the plurality of cavities in the rotor core further comprises releasing the gripping of, by the IAR system, the one or more magnetizable inserts into the one or more cavities, wherein the one or more magnetizable inserts independently descend into the one or more cavities.

11 . A method for assembling a plurality of rotor cores of an electric converter by a central robotic system, the method comprising:

providing the central robotic system that includes a core controller, an insert assembly robotic (IAR) system that includes an IAR controller, and a central controller;

placing a rotor core of the plurality of rotor cores on a mandrel by the central robotic system, wherein the rotor core further comprises a plurality of cavities;

employing a first force control feedback from the core controller of the central robotic system to the central controller and the IAR controller;

placing a plurality of magnetizable inserts into the plurality of cavities in the rotor core by the IAR system employing a second force control feedback; and

adjusting a movement of a robotic arm of the central robotic system, an insert assembly robot of the IAR system, or a combination thereof based on the first force control feedback, the second force control feedback, or a combination thereof so that a detected force coincides with a defined value or profile.

12 . The method of claim 11 , wherein the placing the plurality of magnetizable inserts into the plurality of cavities of the rotor core further comprises:

gripping, at a first orientation, one or more magnetizable inserts from the plurality of magnetizable inserts by the robotic arm of the IAR system; and

aligning and positioning, at a second orientation different from the first orientation, the one or more magnetizable inserts at one or more cavities among the plurality of cavities based on the second force control feedback detected by the IAR system.

13 . The method of claim 12 , wherein the placing the plurality of magnetizable inserts into the plurality of cavities in the rotor core further comprises releasing the gripping of, by the IAR system, the one or more magnetizable inserts into the one or more cavities, wherein the one or more magnetizable inserts independently descend into the one or more cavities.

14 . The method of claim 11 , wherein the plurality of magnetizable inserts includes a first set of magnetizable inserts and a second set of magnetizable inserts, wherein the first set of magnetizable inserts is of a different size than that of the second set of magnetizable inserts.

15 . The method of claim 11 , wherein placing the rotor core on the mandrel further comprises:

aligning an alignment feature at an inner diameter of the rotor core with an alignment feature at an outer diameter of the mandrel based on the first force control feedback detected by the core controller of the central robotic system; and

translationally moving the rotor core along the mandrel based on the first force control feedback detected by the core robotic system.