Annular Laminated Stator Core Manufacturing via Segmented Helical Winding
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Solution Overview
Problem
The existing methods for manufacturing large diameter annular components, such as stator cores for electric motors, result in excessive material waste due to the need for a wide steel strip, which is not efficiently utilized, especially with the absence of a rotor core in electrically commutated motors.
Innovation Solution
A method involving a first progressive die assembly to form pole pieces from individual laminations and a second assembly to create a continuous strip with hinge portions, which is wound around a rotary carousel to capture the pole pieces, minimizing material waste by forming a helical strip that is then cut and welded to secure the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual annular laminations are stamped from a strip of steel stock material using known processes, then annular laminated parts can be manufactured, but a relatively large amount of steel material is wasted due to the strip width needing to be at least as large as the outer diameter of the lamination
Solution Approach 1:
The invention divides the annular lamination into multiple identical pole pieces, each formed from a narrower strip. This segmentation allows the use of a strip width smaller than the outer diameter of the complete annular lamination, thereby reducing material waste while maintaining the ability to manufacture the complete annular component through stacking and interlocking the segmented pole pieces.
Solution Approach 2:
The invention transitions from forming a single large annular lamination in one dimension (requiring wide strip) to forming multiple smaller pole pieces that are stacked in the radial dimension. This dimensional change allows the use of narrower strip material while achieving the same functional component through vertical stacking rather than horizontal spanning.
2Loss of substance
If the steel strip width is reduced to minimize material waste, then material efficiency improves, but the ability to form large diameter annular components is compromised
Solution Approach 1:
The invention segments the large diameter annular component into multiple identical pole pieces that can each be formed from narrower strip material. This segmentation enables the use of cost-effective narrower strip while maintaining productivity through the assembly of multiple segments into the complete large-diameter component.
Solution Approach 2:
The invention performs preliminary formation of individual pole pieces from narrower strip before final assembly into the complete annular component. This preliminary action allows efficient use of narrower material during the forming stage, with the final large-diameter structure achieved through subsequent stacking and interlocking operations.
3Ease of operation
If traditional stamping methods are used with wide steel strip, then large diameter annular components can be formed, but material between adjacent laminations and within the interior of each lamination is wasted
Solution Approach 1:
The invention segments the annular component into multiple pole pieces formed from narrower strip, eliminating the need for wide strip that creates material waste. The segmentation allows precise material utilization where each pole piece is formed from optimized strip width, and the complete annular structure is achieved through assembly of these efficient segments.
Solution Approach 2:
The invention moves from horizontal material utilization (wide strip spanning the diameter) to vertical material utilization (stacking multiple pole pieces). This dimensional transition eliminates waste between adjacent laminations by forming each pole piece from optimized narrower strip, with the complete structure built through radial stacking.
Data Source
AI summary
An apparatus and method for the production of relatively large diameter annular components, such as stator cores for electric motors, without excessive waste of material. In one embodiment, a first progressive die assembly forms a plurality of identical pole pieces each made of a plurality of individual stacked and interlocked laminations. The pole pieces, having protruding end portions, are loaded into a rotary carousel. A second progressive die assembly forms a continuous strip including a plurality of body segments connected via hinge portions disposed adjacent recesses between the body segments that are dimensioned to receive the protruding ends of the pole pieces. As the continuous strip is formed, it is wound about the rotary carousel with progressive pivoting of the body segments about the hinge portions to capture the protruding ends of the pole pieces within the recesses, with continued winding of the strip in a helical fashion around the rotary carousel continuing until a desired height is reached that is substantially equivalent to the height of the pole pieces. The strip is then cut, and the resulting annular part is welded at one or more locations to secure the components together.