Title of Invention	"AN AUTOMATIC MAGNETISING,CHECKING AND FIXING DEVICE FOR MAGNETS OF DC MICROMOTORS"
Abstract	This invention relates to an automatic magnetising, checking and fixing device for magnets of DC micromotors which enables a high throughput of inner casings fitted with magnet ring with a marked reduction in rejection of the finished micromotors in production line and after sales. The device comprises two indexing discs (D1 and D2) having plurality of stations (Si-Sis), a number of jigs (11, 12, 13, 5, 17, 3, 4, 6), vibrating hopers (8, 1) and flux checking unit (14) in which various steps of operation are automated using a plurality of pneumatic cylinders (P1-P10) controlled by a timer. One embodiment of the invention is capable of completing one cycle comprising magnetizing checking the magnet ring and fixing the acceptable magnets into an inner casing in 2 seconds.

Title of Invention

"AN AUTOMATIC MAGNETISING,CHECKING AND FIXING DEVICE FOR MAGNETS OF DC MICROMOTORS"

Abstract

This invention relates to an automatic magnetising, checking and fixing device for magnets of DC micromotors which enables a high throughput of inner casings fitted with magnet ring with a marked reduction in rejection of the finished micromotors in production line and after sales. The device comprises two indexing discs (D1 and D2) having plurality of stations (Si-Sis), a number of jigs (11, 12, 13, 5, 17, 3, 4, 6), vibrating hopers (8, 1) and flux checking unit (14) in which various steps of operation are automated using a plurality of pneumatic cylinders (P1-P10) controlled by a timer. One embodiment of the invention is capable of completing one cycle comprising magnetizing checking the magnet ring and fixing the acceptable magnets into an inner casing in 2 seconds.

Full Text	FIELD OF INVENTION This invention relates to an automated magnetising, checking and fixing device for DC micromotor which performs the functions of magnetising, checking magnetised ring for its BH curve, inserting into inner casing of the motor and fixing the magnet into the casing only when it is perfectly magnetised and rejecting it if it is not properly magnetised. PRIOR ART The magnets used in DC micromotors are magnetized in magnetising jigs. The magnets are then checked 100% manually for flux. The accepted and rejected magnets are manually segregated. Location of magnetic poles is marked manually on the accepted magnets which are then loaded one by one into the inner casing, are aligned and assembled into it by using a press. 100% manual inspection of the magnets for flux is very time consuming and needs dedicated manpower. Assembly of accepted magnet into the casing is also labour intensive. There is every possibility of sub standard magnets getting assembled into motor housing due to known phenomenon of'inspection fatigue' associated with 100% inspection. This results in rejection of finished DC micromotors. QBJECTS OF PRESENT INVENTION An object of the present invention is to provide an automated magnetising and checking device for DC micromotor Another object of the present invention is to provide an automated magnetising device which performs functions of magnetising, the magnet ring, checking magnetised magnet ring for its BH curve before inserting it into inner casing of the motor when it is perfectly magnetised and rejecting it when it is not properly magnetised Still another object of the present invention is to provide an automated magnetising, checking and fixing device for production of DC micromotor which gives maintenance free service over a long period of time Yet further object of the present invention is to provide an automated magnetising, checking and fixing device for DC micrometer which has higher productivity of magnetising, inspection and fitment taking only 2 seconds to perform complete sequence of operations. Still further object of the present invention is to provide an automated magnetising, checking and fixing device which enables throughput of the order of 1800 Nos/hour magnets as compared to 550 Nos/hour in manual magnetising, checking, sorting and fixing using 3 persons. Even further object of the present invention is to provide an automated magnetising, checking and fixing device which has an accuracy of ±5 maxwell as compared to the accuracy of ±10 maxwell achievable in manual operation, which is not desirable due to high rejection of DC micromotors on production line as well as after sales. Yet further object of the present invention is to provide a fully automated device which does not require any dedicated lull time manpower resource to operate. Still further object of the present invention is to provide an automated device which enables to reduce the rejection rate from 2-4% in manual operation to only 0.1% with the present device. Even further object of the present invention is to provide an automated magnetising, checking and fixing device which has low cost of operation. Still further object of the present invention is to provide an automated magnetising, checking and fixing device which is highly reliable which enables 100% inspection of magnets i.e no magnet remains uninspected and no defective magnet gets passed and fitted DESCRIPTION OF ACCOMPANYING FIGURES The device of the present invention is illustrated with accompanying figure (fig l)which illustrates an embodiment of the present invention. It is to be understood that the features and concepts of the invention can be adapted to various embodiments by making changes, adaptations, modifications by those skilled in the art. Such variant embodiments are intended to be within the scope of the present invention. The accompanying figure (Fig. 1) illustrates the overall block diagram of the device. STATEMENT OF INVENTION According to this invention, there is provided an automated magnetising, checking and fixing device for magnets of DC micromotors comprising magnetising jigs, magnetic flux checking device, assembly jigs, characterised in that: the said device comprises two indexed discs (D1 and D2) rotatably mounted and indexable by separate stepper motors, two vibratory hoppers (8,1) each connected to a chute (9, 2), magnet loadingjig (10), inner casing loading jig (3), a plurality of magnetising jigs (11, 12, 13), a magnetic flux checking unit (14), a rejected magnets sorter (17), inner casing radial positioning jig (4), fitting jig (5, 6) for fixing the accepted magnets into inner casings, ejector (7) for ejection of completed inner casings, rejected magnets and chutes for completed inner casings and rejected magnets (15); the said indexed discs (D1, D2) provided with a plurality of stations (S1 to S18), the said discs being mechanically coupled with stepper motor for alignment of said stations with the said magnetising jig; programmable timer being provided for controlling the time of indexing operations DESCRIPTION OF INVENTION WITH REFERENCE TO DRAWINGS Referring to fig 1, the device uses two indexing discs (D1, D2). The magnetising disc (D1) handles motor magnets and fixing disc (D2), handles outer casings The magnetising disc gets loaded with a unmagnetised ring one by one from a vibrating hopper (8) and a chute (9) The said rings undergo magnetisation in one out of three magnetising jigs sequentially. These magnetising jigs (11, 12 13) with their own independent charging units magnetise the magnets in a cyclic order at an interval of about 2 seconds thereby creating a time gap of 6 seconds for each charging unit to allow cooling After magnetisation is carried out, the magnets are checked for flux by the Magnetic Flux Checking Unit (14). The flux value of each magnet is recorded and this recorded value is utilised for automated 'Go' or No Go' decision for insertion into a casing or for rejection The accepted magnets are pressed into inner casing by fixing Jig (5) and the rejected castings are pressed down into chute (15) by rejected magnet sorter jig (17). In the present embodiment the magnetising disc has 12 stations (S1 to 812) for performing various functions The inner casings are loaded into a vibratory hopper (1), get arranged in a moving tine in a chute (2) and are fed one by one into a casing holder on the fixing disc (D2) by inner casing loading jig (3). A motorised jig (4) aligns the casing with respect to the polar axis of the magnet. The magnet is then half pressed into the casing using fixing jig (5), then full pressed using fixing jig (6) and completed casings are ejected by the ejector (7) The complete casing.s go to a bin through chute (16), The fixing disc of the present embodiment has 6 stations (813 to Sis) for performing various operations. The device is provided with programmable timers for controlling the time of indexing discs To facilitate automation a plurality pneumatic cylinders (Pi to PIO) are provided which are controlled for operation timings and sequence by timer. The device has a plurality of power supplies for supplying the electric power to timer, stepper motor, vibratory hopper, chutes, pneumatic cylinders, magnetising jigs, checking unit and various jig The device concurrently performs various operations such as segregation, cleaning, magnetising, flux checking, casing alignment, transfer, pressing, rejection of defectives and enables a cycle time of as low as 2 seconds. WE CLAIM 1 An automated magnetising, checking and fixing device for magnets of DC micromotors comprising magnetising jigs, magnetic flux checking device, assembly , characterised in that: the said device comprises two indexing discs (Dj and D2) rotatably mounted and indexable by separate stepper motors, two vibratory hoppers (8 ,1) each connected to a chute (9, 2), magnet loading jig (10), inner casing loading jig (3), a plurality of magnetising jigs (11, 12, 13), a magnetic flux checking unit (14), a rejected magnets sorter (17), inner casing radial positioning (4), fixing jig (5, 6) for fixing the accepted magnets into inner casings, ejector (7) for ejection of completed inner casings and chutes for completed inner casings(16) and rejected magnets (15); the said indexed discs (Di, D2) are provided with a plurality of stations (Sj to Sig); the said discs being mechanically coupled with stepper motor for alignment of said stations with the said magnetising jigs, the flux checking unit, said rejected magnets sorter and the said fixing jigs, programmable timer being provided for controlling the time of indexing operations. 2. An automatic magnetising, checking and fixing device for magnets of DC micromotors as claimed in claim 1 wherein the magnet loading jig, the inner casing loading jig, the plurality of magnetising jig, the magnetic flux, checking unit, the rejected magnet sorter, the fixing jig, and the ejector for ejection of complete casing are provided with pneumatic cylinders (Pi to Pio respectively) electrically connected with the said timers for automating the operation of said device. 3. Au automatic magnetising, checking and fixing device for magnets of DC micromotors as claimed in claim 1 or 2 wherein number of magnetising jigs is preferably three. 4. Au automatic magnetising, checking and fixing device for magnets of DC micromotors substantially as herein described and illustrated in accompanying drawing.

Full Text

FIELD OF INVENTION
This invention relates to an automated magnetising, checking and fixing device for DC micromotor which performs the functions of magnetising, checking magnetised ring for its BH curve, inserting into inner casing of the motor and fixing the magnet into the casing only when it is perfectly magnetised and rejecting it if it is not properly magnetised.
PRIOR ART
The magnets used in DC micromotors are magnetized in magnetising jigs. The magnets are then checked 100% manually for flux. The accepted and rejected magnets are manually segregated. Location of magnetic poles is marked manually on the accepted magnets which are then loaded one by one into the inner casing, are aligned and assembled into it by using a press.
100% manual inspection of the magnets for flux is very time consuming and needs dedicated manpower. Assembly of accepted magnet into the casing is also labour intensive. There is every possibility of sub standard magnets getting assembled into motor housing due to known phenomenon of'inspection fatigue' associated with 100% inspection. This results in rejection of finished DC micromotors.

QBJECTS OF PRESENT INVENTION
An object of the present invention is to provide an automated magnetising and checking device for DC micromotor
Another object of the present invention is to provide an automated magnetising device which performs functions of magnetising, the magnet ring, checking magnetised magnet ring for its BH curve before inserting it into inner casing of the motor when it is perfectly magnetised and rejecting it when it is not properly magnetised
Still another object of the present invention is to provide an automated magnetising, checking and fixing device for production of DC micromotor which gives maintenance free service over a long period of time
Yet further object of the present invention is to provide an automated magnetising, checking and fixing device for DC micrometer which has higher productivity of magnetising, inspection and fitment taking only 2 seconds to perform complete sequence of operations.
Still further object of the present invention is to provide an automated magnetising, checking and fixing device which enables throughput of the order of 1800 Nos/hour magnets as compared to 550 Nos/hour in manual magnetising, checking, sorting and fixing using 3 persons.
Even further object of the present invention is to provide an automated magnetising, checking and fixing device which has an accuracy of ±5 maxwell as compared to the accuracy of ±10 maxwell achievable in manual operation, which is not desirable due to high rejection of DC micromotors on production line as well as after sales.
Yet further object of the present invention is to provide a fully automated device which does not require any dedicated lull time manpower resource to operate.
Still further object of the present invention is to provide an automated device which enables to reduce the rejection rate from 2-4% in manual operation to only 0.1% with the present device.
Even further object of the present invention is to provide an automated magnetising, checking and fixing device which has low cost of operation.
Still further object of the present invention is to provide an automated magnetising, checking and fixing device which is highly reliable which enables 100% inspection of magnets i.e no magnet remains uninspected and no defective magnet gets passed and fitted
DESCRIPTION OF ACCOMPANYING FIGURES
The device of the present invention is illustrated with accompanying figure (fig l)which illustrates an embodiment of the present invention. It is to be understood that the features and concepts of the invention can be adapted to various embodiments by making changes, adaptations, modifications by those skilled in the art. Such variant embodiments are intended to be within the scope of the present invention. The accompanying figure (Fig. 1) illustrates the overall block diagram of the device.
STATEMENT OF INVENTION
According to this invention, there is provided an automated magnetising, checking and fixing device for magnets of DC micromotors comprising magnetising jigs, magnetic flux checking device, assembly jigs, characterised in that: the said device comprises two indexed discs (D1 and D2) rotatably mounted and indexable by separate stepper motors, two vibratory hoppers (8,1) each connected to a chute (9, 2), magnet
loadingjig (10), inner casing loading jig (3), a plurality of magnetising jigs (11, 12, 13), a magnetic flux checking unit (14), a rejected magnets sorter (17), inner casing radial positioning jig (4), fitting jig (5, 6) for fixing the accepted magnets into inner casings, ejector (7) for ejection of completed inner casings, rejected magnets and chutes for completed inner casings and rejected magnets (15); the said indexed discs (D1, D2) provided with a plurality of stations (S1 to S18), the said discs being mechanically coupled with stepper motor for alignment of said stations with the said magnetising jig; programmable timer being provided for controlling the time of indexing operations
DESCRIPTION OF INVENTION WITH REFERENCE TO DRAWINGS
Referring to fig 1, the device uses two indexing discs (D1, D2). The magnetising disc (D1) handles motor magnets and fixing disc (D2), handles outer casings The magnetising disc gets loaded with a unmagnetised ring one by one from a vibrating hopper (8) and a chute (9) The said rings undergo magnetisation in one out of three magnetising jigs sequentially. These magnetising jigs (11, 12 13) with their own independent charging units magnetise the magnets in a cyclic order at an interval of about 2 seconds thereby creating a time gap of 6 seconds for each charging unit to allow cooling After magnetisation is carried out, the magnets are checked for flux by the Magnetic Flux Checking Unit (14). The flux value of each magnet is recorded and this recorded value is utilised for automated 'Go' or No Go' decision for insertion into a casing or for rejection The accepted magnets are pressed into inner casing by fixing
Jig (5) and the rejected castings are pressed down into chute (15) by rejected magnet sorter jig (17). In the present embodiment the magnetising disc has 12 stations (S1 to 812) for performing various functions
The inner casings are loaded into a vibratory hopper (1), get arranged in a moving tine in a chute (2) and are fed one by one into a casing holder on the fixing disc (D2) by inner casing loading jig (3). A motorised jig (4) aligns the casing with respect to the polar axis of the magnet. The magnet is then half pressed into the casing using fixing jig (5), then full pressed using fixing jig (6) and completed casings are ejected by the ejector (7) The complete casing.s go to a bin through chute (16), The fixing disc of the present embodiment has 6 stations (813 to Sis) for performing various operations.
The device is provided with programmable timers for controlling the time of indexing discs To facilitate automation a plurality pneumatic cylinders (Pi to PIO) are provided which are controlled for operation timings and sequence by timer.
The device has a plurality of power supplies for supplying the electric power to timer, stepper motor, vibratory hopper, chutes, pneumatic cylinders, magnetising jigs, checking unit and various jig
The device concurrently performs various operations such as segregation, cleaning, magnetising, flux checking, casing alignment, transfer, pressing, rejection of defectives and enables a cycle time of as low as 2 seconds.

WE CLAIM
1 An automated magnetising, checking and fixing device for magnets of DC
micromotors comprising magnetising jigs, magnetic flux checking device, assembly , characterised in that:
the said device comprises two indexing discs (Dj and D2) rotatably mounted and indexable by separate stepper motors, two vibratory hoppers (8 ,1) each connected to a chute (9, 2), magnet loading jig (10), inner casing loading jig (3), a plurality of magnetising jigs (11, 12, 13), a magnetic flux checking unit (14), a rejected magnets sorter (17), inner casing radial positioning (4), fixing jig (5, 6) for fixing the accepted magnets into inner casings, ejector (7) for ejection of completed inner casings and chutes for completed inner casings(16) and rejected magnets (15);
the said indexed discs (Di, D2) are provided with a plurality of stations (Sj to Sig); the said discs being mechanically coupled with stepper motor for alignment of said stations with the said magnetising jigs, the flux checking unit, said rejected magnets sorter and the said fixing jigs, programmable timer being provided for controlling the time of indexing operations.
2. An automatic magnetising, checking and fixing device for magnets of DC micromotors as claimed in claim 1 wherein the magnet loading jig, the inner casing loading jig, the plurality of magnetising jig, the magnetic flux, checking unit, the rejected magnet sorter, the fixing jig, and the ejector for ejection of complete casing are provided with pneumatic cylinders (Pi to Pio respectively) electrically connected with the said timers for automating the operation of said device.
3. Au automatic magnetising, checking and fixing device for magnets of DC micromotors as claimed in claim 1 or 2 wherein number of magnetising jigs is preferably three.
4. Au automatic magnetising, checking and fixing device for magnets of DC micromotors substantially as herein described and illustrated in accompanying drawing.

Documents:

1310-DEL-2002-Abstract-(24-09-2008).pdf

1310-del-2002-abstract.pdf

1310-DEL-2002-Claims-(24-09-2008).pdf

1310-del-2002-claims.pdf

1310-DEL-2002-Correspondence-Others-(11-11-2008).pdf

1310-DEL-2002-Correspondence-Others-(24-09-2008).pdf

1310-del-2002-corrrespondence-others.pdf

1310-del-2002-corrrespondence-po.pdf

1310-del-2002-description (complete).pdf

1310-del-2002-drawings.pdf

1310-del-2002-form-1.pdf

1310-del-2002-form-18.pdf

1310-DEL-2002-Form-2-(24-09-2008).pdf

1310-del-2002-form-2.pdf

1310-DEL-2002-Form-3-(24-09-2008).pdf

1310-del-2002-form-3.pdf

1310-del-2002-form-4.pdf

1310-del-2002-form-5.pdf

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Patent Number

225675

Indian Patent Application Number

1310/DEL/2002

PG Journal Number

13/2009

Publication Date

27-Mar-2009

Grant Date

19-Nov-2008

Date of Filing

30-Dec-2002

Name of Patentee

THE SECRETARY

Applicant Address

DEPARTMENT OF INFORMATION TECHNOLOGY, MINISTRY OF COMMUNICATION & INFORMATION TECHNOLOGY, GOVERNMENT OF INDIA, ELECTRONICS NIKETAN, 6, CGO COMPLEX, LODHI ROAD, NEW DELHI-110 003.

Inventors:

#	Inventor's Name	Inventor's Address
1	BUDH SINGH SETHIA	ELIN ELECTRONICS LTD., 4771, BHARATRAM ROAD, 23 DARYAGANJ, NEW DELHI-110002.
2	N. S. BHALLA	INSTEL ELECTRONICS PVT. LTD., 1/2, WEST PATEL NAGAR, NEW DELHI-110008.

PCT International Classification Number

G11B 7/09

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA