NIDEC and HONDA - Ex. 1020
`Nidec Corporation and American Honda
`Motor Co., Inc. - Petitioners
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`Ross Will Stun the World
`with Praise For
`' “3
`President Clinton...
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`Just imagine...20,000 proven buyers and product
`specifiers... jamming the exhibit floor...checking out the
`latest in automatic assembly systems, power and hand tools,
`machine vision, robotics, bar coding, fasteners, electrical/
`electronics and assembly hardware...from more than
`32 S manufacturers.
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`...bef0re you’ll firm or Better marketing opportunity
`than ASSEMBLY Technology Expo ’94!
`
`ers
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`3570313 f
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`Sponsored by
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`ASSEMBLY,
`magazine
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`ASSEMBLY Technology Expo ’94.
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`They’ll see your competitors there...wili they see you?
`
`Complete and FAX the form on the back of this page — or
`call LuRae Breyer at 800323-5155 TODAY — for complete
`attendee profile statistics and exhibitor space options.
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`It‘>ettteet
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`EXPO...
`September 27 — 29, 1994
`Rosemont Convention Center
`Rosemont (Chicago), Illinois USA
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`einvention. It’s today's buzz word. President
`J Clinton talks about reinventing big government.
`And companies from IBM to mom-and—pop
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`I “ng. enterprises are reengineering themselves—
`redesigning processes, strucmre. and culture—to
`compete in a tough economy.
`To steer a proper course, a company needs to
`understand its most detailed workings, says Leonard
`Bertain. He heads a productivity consulting firm and
`authored 1739 New Turnaround, a “business novel"
`based on his experiences.
`"A company needs to understand the degree to
`which its current processes and culture are a part of
`the problem,” says Dr. Bertain. “Only then can meaningful reinvention occur.“
`He feels that many companies are confused by the business cultures they have
`Created. The ideas that helped them grow and sucreed in the past now hinder
`them.
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` No Blame, Big Gains
`
`“Big companies achieved revenue growth, but didn’t grow in their abiiity to
`effectively adapt to change. And small companies that copied big companies have
`often downsized in lock—step with them,” Dr. Bertain explains.
`Lack of ideas doesn’t deter companies from becoming high performers. What’s
`lacking. he says. is a clear understanding of what to change and how to
`implement change.
`One of the biggest barriers to becoming competitive, Dr. Bertain continues, is
`that people spend too much time placing blame. and defending sacred cows.
`“When management and labor are not pointing fingers at each other, they are
`pointing at unfair foreign competition, inequitable trade practices, government
`regulation, lack of government regulation, overehyped productivity philosophies—
`and just about anything else that will distract attention from industry’s collective
`reaponsibility,“ Dr. Bertain asserts.
`“TQM, JTI', SPC, TOC, and synchronous manufacturing are all useful tools for
`dealing with the demands of the competitive global marketplace. They are not the
`problem. It is the assumptions built into our business culture that have tainted our
`adaptation of these improvement philosophies.”
`For example, he says, the majority of American managers feel that thinking is
`not part of most workers’ job descriptions. Dr. Bertain proposes a prerequisite for
`meaningful, long—term improvement: a strong, no—blame approach “to set aside
`fears, and facilitate progress."
`Perhaps your company should encourage all employees to work together in a
`positive, no-blame environment to reinvent the kind of culture that you need to
`succeed. There is nothing to lose, except the barriers between you and the big
`gains that come from no blame,
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`Maw 94 ASSEMBLY—5
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`ELECTRICAL MANUFACTURING AND COIL WINDING
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`Molded Parts
`Speed Motor Assembly
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`Motor manufacturers increasingly use engineering plastics
`to develop stator advancements.
`W.J. Hassink
`Senior Development Specialist
`W.E. Kenney
`Senior Design Specialist
`J. Deeble
`Laboratory Representative
`DuPont Polymers
`Wilmington. DE
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`ecent innovations in motor design
`use engineering plastics. For sta—
`tors, motor manufacturers are fol—
`lowing two main paths to reduce
`costs and improve reliability with engi-
`neering plastics. One path involves sepa-
`rately molded multifunctional components;
`the other employs insert molding to encap—
`sulate the stator, while simultaneously build—
`ing in assembly functions.
`Driven by needs to hold down costs
`and improve reliability, motor manufactur—
`ers increasingly integrate engineering plas—
`tics into their products.
`in papers pre—
`sented at recent EMCWA conferences, we
`have reported innovations in several areas:
`I Multifunctional end brackets that inte—
`grate insulation, structural, bearing. and
`assembly features;
`I Bearings mat eliminate separate lu—
`brication;
`I Rotors and stators using molded com—
`ponents to replace paper. film. thermosets,
`or other traditional materials.
`Recently the pace of innovation has
`quickened in stator design and construc-
`tion. Producing traditional stator designs is
`highly labor intensive. It requires handling
`and placement of flexible slot insulators,
`and other components such as pultnided
`therrnoset pins or tie cords. to secure field
`coils to laminations. Terminating the field
`coil's magnet wire to a lead wire is often a
`manual operation.
`To reduce stator assembly costs, motor
`makers are increasingly turning to engi-
`neering plastics—either separately molded
`components or encapsulation materials
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`Figure 1: Molded stator parts ior washer
`motor.
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`Multiluuotional stator parts
`Separately molded stator components
`of engineering plastics offer several ways
`to cut assembly costs, while allowing use
`of the same parts in different motors.
`Recently. several motor manufacturers
`have adopted molded end insulators with
`integral pockets for automated termina-
`tion. The pockets offer a notch or slot to
`hold the magnet wire end while a machine
`inserts a metal terminal. Such components
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`Figure 2: Assembled stator lor washer
`motor.
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`34-ASSEMBLY May i' 94
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`are used in stators employing conventional
`flexible slot insulation
`Motor builders can further economize
`on labor input by eliminating flexible slot
`insulation, and by integrating that function
`into a combination endr'slot insulating com—
`ponent. ”the parts shown in Figure 1 reflect
`dais approach. They are used in the stator
`(shown partially assembled in Figure 2') for
`a universal motor that powers l-ineie of
`Germany washing machines.
`The larger, more complex Miele cr1111p0~
`nents integrate end and slot
`insulationr
`termination holders, and provisions for snap-
`lock assembly. Another part at the opposite
`end of the lamination stack from tire larger
`component has integral snap—locking de-
`tents and coil. supports, too.
`Both components are injection molded
`in an unreinforced 6,6 nylon resin part of
`a pretested. preapprovecl ULClass ii '3 130%? ::
`system evaluated in according to ii-‘t‘. Pub-_
`lication 85. This saved the manuiacturer:
`time in obtaining necessary :tppl‘Ui'iils [0.
`meet electrical safety requirements of van--
`ous countries.
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`Encapsulation: one-step production _
`Given sufficient volume to recto“?r 50°, --
`ing costs, insert molding technulf-‘sl' Off-3’
`me ultimate in designing stators tor ‘rl U}.
`"
`mum of assembly steps and coil- L
`process involves placing the steel 1715‘,“
`tions in an injection mold, and that!
`the mold with thermoplastic Wilma
`single step, the process locks Elle [ad‘sl
`Lions
`together and forms and (mf-
`insulation. coil supports. and .ici-L‘ll'lb 3 -
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`ELECTRICAL MANUFACTURING AND COIL aniNG
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`terminal
`titres such as winding guides,
`holders. screw bosses. and mountingbrack—
`ets components.
`Besides cutting costs. insert molding is
`simple and relatively easy to control. By
`eliminating various separate components
`and operations. it avoids multiplication of
`telerances, and thus promotes consistency
`of r1ruality and product reliability.
`Several examples show how motor
`manufacturers use insert molding to achieve
`the features and benefits of thermoplastic
`encapsulation.
`I AC induction motors. The stators
`shown in Figures 3 and ti serve in AC
`induction motors for fans for commercial
`refrigeration equipment. Both were devel
`oped by Electric Motors and Specialties.
`inc. iEMSrS). Garrett, LN.
`The unit in Figure 3 is for a 10 W, split—
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`Fiuure 3: Encapsulated stator tor 1|] to
`5Fill! capacitor motor.
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`:ntiouul
`inortuze
`ible lei
`11m Eit’in
`ng com—
`1 reflect
`1e stator
`re 2 t for
`their: of
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`- con ! po-
`suizluon.
`for snap-
`oppr site
`he Luger
`it i on; de-
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`l molded
`1, purl of
`B: : WC)
`IL‘t. Pub-
`utLu‘turer
`.1‘(_,I\".‘rlli
`[O
`[5' tir' vari-
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`' capacitor motor for condenser fans, The
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`islotfend encapsulation part has integral
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`.posts that double as supports for a terminal
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`board and as winding guides.
`lotion
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`_ EM&S formerly encapsulated an earlier
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`t_)\ or [001'
`ifirsion of this stator with an epoxy pow—
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`355' Offers
`' ‘18? system. Switching to thermoplastic
`or .t init'li'
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`' FHPsulation reduced costs by eliminat—
`iii-L. The .
`glhe need to tumble-Finish and preheat
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`aminate cores prior to coating.
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`Elle stator in Figure 4 is for a 25 W
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`sded pole motor. In addition to end and
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`Iisolation. the one—piece design incor-
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`rates contoured winding slots for accu-
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`iPlacement of windings, and pem‘lits
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`Figure 4: Encapsulated stator tor 25 W
`shaded pole motor.
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`effective use of slot space. Termination
`holders are also integrated in the design.
`in a previous construction, the stator
`used a paper/film composite for slot insu-
`lation, and separate parts for coil supports,
`end insulation, and termination holders.
`Thermoplastic encapsulation reduced pan
`and assembly costs while improving qual-
`ity, says EM&S.
`Both stator designs are encapsulated
`with a nylon resin. It provides high produc-
`tivity in the insert molding process. and is
`part of a pie—approved insulation system
`for Class B (130°C) service under the UL
`1446 standard.
`I Universal motor. The stator shown
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`at the right in Figure 3 is for a universal
`motor used in a meat grinder produced by
`S.E.B. of France. The encapsulation mate—
`rial not only provides end insulation but
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`fulfills structural and assembly functions.
`The coil supports at both ends have
`integral flanges to fix the magnet wire's
`position Slotted termination pockets hold
`magnet wire ends and are configured to
`hold standard metal terminals. Through
`holes facilitate subsequent assembly of the
`stator to end brackets.
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`The resin used is a mermoplastic poly—
`ester. flame-retardant material based on
`polyethylene terephthalate (PET). It is part
`of preapproved UL 1446 systems for ser-
`vice up to Class N (200°C). S.E.B.'s meat
`grinder motor is engineered for Class {-1
`(180°C) service.
`The end bracket and spider shown at
`the left and center of Figure 5 are injection
`molded of the same material. The bracket
`design also incorporates numerousmolded—
`in functions. They include an integral bear—
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`
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`Figura B: New brushlcss DC washer motor
`uses large encapsulated components.
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`ing pocket. retainer poots for the brush
`spring. fingers for a capacitor, brush wells,
`several screw bosses, and a mounting
`bracket,
`I Novel DC brushless motor. New
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`Zealand’s leading appliance maker, Fisher
`3: Paykel Co. has implemented automa-
`tion opportunities of insert molding in a
`radically" new kind of brushless DC motor.
`Used in washing machines, it (Figure 6) is
`electronically controlled and directly drives
`the washer’s agitator and spin bowl through
`a patented clutch. This eliminates a com-
`plex gear case required with a fixed—speed
`AC motor.
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`Figure 5: Encapsulated stator, cud bracket,
`and spider tor moat prlnuar motor.
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`lta'ltty'ir 94 ASSEMBLYffl
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`' tom Cort. "iii-"131mm
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`Figure 7: Encapsulated stator tut
`hrushless uc washer mutur.
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`Wheel-shaped. the motors stator tFig—
`ure 7) measures about 25 cm t‘M-l
`in.)
`across.
`its lamination Staci; resembles a
`specially prol'iled ring. When placed in the
`mold. the insert molding process produces
`the stator's support structure. ground insu—
`lz-trion. and L'Ull support-t in a single step.
`The design includes -'i2 integrally molded
`winding poles spaced around its circume
`ferenee. Other molded-in features include
`wire wart-'5‘ terminal holders, and holes for
`mounting bolts and drainage.
`The rotortFigure Si is also insert molded.
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`This dish-shaped component measures
`about 27' cnt tin": in.)
`in diameter and
`rotates around the stator. integrally molded
`teeth in the hut; mate with the spline end
`or" a steel shaft that :spins the washer rut)
`and moves the agitator.
`Polyester resins based on PET are used
`l‘ur hoth components. The rotor resin has
`4‘3"” glass reinforcement. The stator mate—
`rial
`is a flatrteereturdant lorrnultt with tfi'f’iu
`reinforcement.
`Both formulas provide high stiffness
`and strength plus creep reeistttnee required
`in the large, heavy assemblies. in the stator.
`the thermoplastic material
`is subject
`to
`hettjr static loads in supporting about 5 kg
`(0.6 lb} of windings and steel leminations.
`'l‘he rotor withstands dynamic torsional
`and radial loading as it oscillates Ell variable
`speeds in a 200° are during agitation circles‘
`and Whitls up to i100 rpm during spin
`cycles.
`Although F&P's patented motor is an
`unusual design.
`it holds valuable lessons
`for other types of motors. It is an outstand-
`ing example of eonsolidaLing multiple hint--
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`Figure B: Encapsulated rutur tor liruslitess
`uc washer motor.
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`tione in engineering plastics putts—rind it
`underscores the value of rethinking trad]:
`[tonal motor design.
`in the LS. and
`Motor manufacturer";
`abroad :tre reducing costs and imprm ing
`the reliability of stators by building mul—
`tiple insulation. assemhly. 11nd Sittictltrtti
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`functions into Engttluctlilgeplflfilics '
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`.prt
`nertts. Benefits derive from either
`rtttely molded components or e11t‘.up~:=,ria-
`tion techniques. The choice L‘lt‘PL‘iiilw on
`production volume and other factor». melt
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`as plant layout and motor design.
`fi
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`Formulated for
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`nmuill'réihnoe-Ti:
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`Irm'fllumlnunt -
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`The Hard-men product line of
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`CHEMICALS INC-
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`The right adhesive for your
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` CIRCLE 376 on reader information card
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`SIS—ASSEMBLY Matt t' 94
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`6
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