Claims:We claim,

1. An improved Magneto Rotor assembly (100) and the process of manufacturing thereof comprising of taper bush/hub (102), two sheets in form of rings made of MS Steel and plurality of magnets (112);
characterized in that
one sheet of ring having a flat surface forms the inner cup ring (104) and other sheet of ring forms the outer PIP ring (106); and
the said PIP ring (106) has window pockets or windows (108) and the columns formed between the adjacent windows (108) on the outer PIP ring (106) are the PIP (110); and
the plurality of magnets (112) are attached to the inner surface of the cup ring (104); and
a steel sleeve (114) covers the magnets in the said magneto rotor assembly (100).

2. The improved Magneto Rotor assembly (100) as claimed in claim 1, wherein the taper bush/hub (102) is made of MS Steel and functions to mount the magneto rotor assembly (100) on the engine crank shaft.

3. The improved Magneto Rotor assembly (100) as claimed in claim 1, wherein the inner cup ring (104) has a flat surface without any embossing or extensions and thus providing more surface area and bonding streng for adhesion of the magnets (112) to the cup ring (104) inner surface.

4. The improved Magneto Rotor assembly (100) as claimed in claim 1, wherein the process of manufacturing the said rotor assembly comprises the following steps:
a. PIP window formation in the PIP ring (106) by progressive stamping process with stamping press machine to form windows (108) and the PIP (110);
b. the PIP ring (106) with the windows (108) and the PIP (110) is welded to the cup ring (104) by CO2 welding or Arc welding or laser welding or Spot welding;
c. placing the welded cup ring (104) and PIP ring (106) subassembly on the taper bush/hub (102);
d. applying adhesive to the inner surface of the cup ring (104) and attaching a plurality of magnets (112) placed at predetermined positions or as required by the manufacturer;
e. applying adhesive on the inner surface of the magnets (112) and pressing the steel sleeve (114) on the inner surface of the magnets (112) such that the steel sleeve (114) completely covers the magnets (112) to obtain the magneto rotor assembly.

5. The improved Magneto Rotor assembly (100) as claimed in claim 1, wherein the said magneto rotor assembly has low manufacturing cost and improved magneto performance.
, Description:FIELD OF INVENTION
The present invention in general relates to a magneto rotor assembly and more particularly it relates to an improved magneto rotor assembly and the process of manufacturing thereof.
BACKGROUND OF THE INVENTION

Flywheels and magneto ignitions are typically installed in vehicles and engines. A magneto is an electromagnetic device that produces alternating current (electrical power) for distribution to the Spark plugs of an engine. A conventional flywheel magneto generator includes a rotor assembly, a Stator assembly and a Pick-up assembly. The rotor assembly has a flywheel and a plurality of poles disposed around the peripheral wall of the flywheel. Permanent magnets are secured by bolts to the poles. A Stator assembly confronts the permanent magnets on the rotor to generate electrical energy. The pick-up assembly is the electrical part of the magneto. When magnetic flux gets cut by the PIP on the rotor assembly, a voltage is generated and this voltage acts as a signal to CDI/TCI/ ECU to ignite the spark plug of the vehicle.
In other flywheel magneto generators, a Single magnet is mounted on the flywheel and the flux of the magnet is brought out to the working radius of the flywheel by pole shoes that are made of a magnetically conductive material. The Stator assembly is typically a U-shaped core that is made of a magnetically conductive material. The ends of the core are positioned close to the path of the poles shoes on the flywheel. The magnet on the rotating flywheel produces a magnetic field through a permeability path provided by the Stator assembly. One or more coils are wrapped around the core. When the flux passes through the core, a Voltage is generated in the coils. This Voltage may be Stored or used to Start an engine. This prior art System was not optimized since flux was generated in the Stator assembly only once for each revolution of the flywheel.
Also, prior art Systems that utilized magnets on the flywheel also were required to find ways to attach the magnet to the flywheel, keeping in mind that the flywheel had to be balanced in order to operate Smoothly. Magnets have been attached by Screws, for instance. Proper balancing of the flywheel rotor is difficult and adds complexity to the system.
Other conventional manufacturing processes for magneto rotor assembly have lesser area for adhesion of magnets to the inner surface resulting in less bonding strength of the magnet with the rotor assembly. This process also leads to crack in the final assembly during machining. Therefore, there is felt a need to provide a simple manufacturing process for magneto rotor assembly having increased bonding strength for magnet adhesion as well as being low cost and with high accuracy.

OBJECTIVES OF THE INVENTION
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present invention is to provide an improved magneto rotor assembly for use in vehicles.
Another object of the present invention is to provide the improved magneto rotor assembly for use in vehicles with easy manufacturing process.
Another object of the present invention is to provide the improved magneto rotor assembly for use in vehicles, having low manufacturing cost and improved magneto performance.
Another object of the present invention is to the improved magneto rotor assembly for use in vehicles, having increased area of adhesion for magnet to increase the bonding strength of the magnet in the magneto rotor assembly .
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

SUMMARY OF THE INVENTION
Before the present invention is described, it is to be understood that present invention is not limited to particular methodologies and materials described, as these may vary as per the person skilled in the art. It is also to be understood that the terminology used in the description is for the purpose of describing the particular embodiments only, and is not intended to limit the scope of the present invention.
The present invention describes an improved magneto rotor assembly and the process of manufacturing thereof. Magneto is an electromagnetic device which generates electrical power for vehicle. Magneto is a combination of three parts that includes Rotor assembly , Stator assembly. & pickup assembly. The magneto rotor assembly is made of taper bush/hub and two sheets in form of rings made of MS steel. The taper bush/hub is made of MS steel and functions to mount the magneto rotor assembly on the engine crank shaft. The inner cup ring (104) has a flat surface and does not have any embossing or extensions. The outer additional ring, also known as PIP ring is made of MS steel. The PIP ring (106) has window pockets or windows formed by sheet metal pressing. The PIP window formation in the PIP ring is done by progressive stamping process with stamping press machine. The columns formed between the adjacent windows (108) on the outer PIP ring are the PIP . The magnets are attached to the inner surface of the cup ring and PIP ring assembly by strong adhesion. Covering all the magnets attached to the cup ring is a steel sleeve that protects the magnets in the magneto rotor assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present invention may be made by reference to the following detailed description which is to be taken in conjugation with the accompanying drawing. The accompanying drawing, which is incorporated into and constitutes a part of the specification, illustrates one or more embodiments of the present invention and, together with the detailed description, it serves to explain the principles and implementations of the invention.
FIG.1 is the front perspective view of the magneto rotor assembly according to an embodiment of the invention;
FIG.2 is the cross sectional view of the magneto rotor assembly as shown in FIG.1 according to the embodiment of the invention;
FIG.3 is the exploded view of the cross section of the magneto rotor assembly as shown in FIG.2 according to the embodiment of the invention;
FIG.4 is the exploded view of the first subassembly of the magneto rotor assembly as shown in FIG.1 according to the embodiment of the invention;
FIG. 5 is the perspective view of the second subassembly of the magneto rotor assembly with Magnet and Steel Sleeve as shown in FIG.4 according to the embodiment of the invention; and
FIG. 6 is the exploded view of the second subassembly of the magneto rotor assembly as shown in FIG.5 according to the embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Before the present invention is described, it is to be understood that this invention is not limited to particular methodologies described, as these may vary as per the person skilled in the art. It is also to be understood that the terminology used in the description is for the purpose of describing the particular embodiments only, and is not intended to limit the scope of the present invention. Throughout this specification, the word “comprises”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results.

LIST OF REFERENCE NUMERALS:

Sr. No. Description of the part
100 Magneto rotor assembly
102 Taper bush/ hub
104 cup ring
106 PIP ring
108 Windows on the PIP ring
110 PIP
112 magnets
114 Steel sleeve

The present invention describes an improved magneto rotor assembly and the process of manufacturing thereof. As mentioned earlier, magneto is an electromagnetic device which generates electrical power for vehicle. Magneto is a combination of three parts that includes Rotor assembly , Stator assembly. & pickup assembly. Pickup assembly is the electrical part of the magneto. When magnetic flux of pickup assembly gets cut by PIP of rotor assembly, a voltage is generated & this voltage acts as a signal to the electronic part which take the signal from pickup assembly and gives the output to ignition coil to ignite the air fuel mixture in the engine head in the vehicle.

Conventionally, the cup ring of the magneto rotor assembly is manufactured using a single sheet of MS steel. This sheet of MS steel is embossed using hydraulic press to create plurality of PIP on the outer surface of the cup ring. Because of this extensions (PIP) on the outer surface, there is a depression created in inner surface of the cup ring. This results in lesser area for adhesion of magnet on the inner surface of the cup ring. This in turn results in less bonding strength of the magnet with the cup ring. Further, at the embossed area in the cup ring, the thickness of Sheet is less which results in chance of crack during machining. The overall cost of manufacturing using this process is more and the accuracy of the PIP formation is uneven to cut the magnetic flux is reduced.

In the given embodiment of the present invention, the improved magneto rotor assembly (100) overcomes the above-mentioned drawbacks found in conventional magneto rotor assembly. In the present embodiment, FIG. 1 is the front perspective view of the magneto rotor assembly. The magneto rotor assembly (100) is made of taper bush/hub (102) and two sheets in form of rings made of MS steel. The taper bush/hub (102) is made of MS steel and functions to mount the magneto rotor assembly (100) on the engine crank shaft. The inner cup ring (104) has a flat surface and does not have any embossing or extensions. The outer additional ring, also known as PIP ring (106) is made of MS steel. The PIP ring (106) has window pockets or windows (108) formed by sheet metal pressing. The PIP window formation in the PIP ring (106) is done by progressive stamping process with stamping press machine. The columns formed between the adjacent windows (108) on the outer PIP ring (106) are the PIP (110).

In the present embodiment of the invention, FIG.2 is the cross-sectional view of the magneto rotor assembly as shown in FIG.1. The magneto rotor assembly (100) comprises of taper bush/hub (102), inner cup ring (104) and outer PIP ring (106). The windows on the PIP ring (108) lead to formation of PIP (110). The PIP ring (106) is strongly welded to the cup ring (104) by CO2 welding or Arc welding or laser welding or Spot welding. Therefore, there is no embossing or extensions on the inner surface of the cup ring (104).

In the given embodiment of the invention, FIG.3 is the exploded view of the cross section of the magneto rotor assembly as shown in FIG.2. The magneto rotor assembly (100) comprises of taper bush/hub (102), inner cup ring (104) and outer PIP ring (106). The windows on the PIP ring (108) lead to formation of PIP (110). The magnets (112) are attached to the inner surface of the cup ring (104) and PIP ring (106) assembly by strong adhesion. Covering all the magnets (112) attached to the cup ring (104) is a steel sleeve (114) that protects the magnets in the magneto rotor assembly (100).

In the given embodiment of the invention, FIG.4 to 6 illustrate the assembly process of the magneto rotor with improved PIP formation. FIG. 4 is the exploded view of the first subassembly of the magneto rotor assembly as shown in FIG.1. The first step is PIP formation in the PIP ring (106). The PIP ring (106) has window pockets or windows (108) formed by sheet metal pressing. The PIP window formation in the PIP ring (106) is done by progressive stamping process with stamping press machine. The columns formed between the adjacent windows (108) on the outer PIP ring (106) are the PIP (110). The PIP ring (106) with the windows (108) and the PIP (110) is welded to the cup ring (104), This welded subassembly is then placed on the taper bush/hub (102).

In the given embodiment of the invention, FIG. 5 is the perspective view of the second subassembly of the magneto rotor assembly with Magnet and Steel Sleeve as shown in FIG.4. There is an adhesive application on the inner surface of the cup ring (104). A plurality of magnets (112) placed at predetermined positions or as required by the manufacturer, are attached to the inner surface of the cup ring (104). Since there is no embossing or extensions on the inner surface of the cup ring (104), this in turn provides more surface area for adhesion of the magnets (112) to the cup ring (104) inner surface. Thereby, increasing the bonding strength of the magnets (112) with the cup ring (104). There is a further adhesive application on the inner surface of the magnets (112). The steel sleeve (114) is then pressed on the inner surface of the magnets (112) and the steel sleeve (114) completely covers the magnets (112). The assembly of the magneto rotor is thus completed.

In the given embodiment of the invention, FIG. 6 is the exploded view of the second subassembly of the magneto rotor assembly as shown in FIG.5. The plurality of magnets (112) are placed at predetermined positions or as required by the manufacturer and are attached to the inner surface of the cup ring (104). The steel sleeve (114) completely covers the magnets (112). The final assembly is then cured at 180 degree Celsius for one hour.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.