Brake Device With Stress Compensation Pockets For Lamination Shearing
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Solution Overview
Problem
Traditional brake devices in shearing moulds for laminar packages experience increased interference between the brake element and the shearing mould due to wear, leading to mechanical stress, breakage, and reduced useful life, causing inefficiencies and increased costs, especially in laminations with 'T' profiles.
Innovation Solution
A brake device with a brake block having an opening smaller than the lamination and mechanical stress compensation means, such as pockets at stress intensification zones, to maintain constant interference and absorb deformations, preventing pickups and breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid brake element with fixed size is used to generate counterforce for lamination packing, then the interference between brake and lamination is initially sufficient, but wear of the shearing profile causes interference to increase over time, leading to brake element breakage and reduced useful life
Solution Approach 1:
The brake element transitions from a rigid fixed-size component to a dynamic structure with pockets that can deform and expand. This allows the brake element to adapt its internal volume and maintain constant interference with the lamination despite wear of the shearing profile, preventing excessive stress accumulation and breakage over time
Solution Approach 2:
The brake element's physical parameters (specifically the volume and shape of internal pockets) change in response to operational conditions. As the shearing profile wears and lamination size increases, the pockets expand to accommodate the increased interference, maintaining optimal contact pressure and preventing brake element failure
2Ease of operation
If the brake element size is reduced to create initial interference for packing, then lamination coupling is enabled, but the same interference mechanism causes excessive stress during operation leading to pickups on the shearing profile and breakage
Solution Approach 1:
The brake element incorporates pockets that act as pre-designed stress absorption zones. These pockets are positioned to absorb mechanical stresses before they can propagate to the shearing profile and cause pickups or breakage, providing beforehand cushioning against harmful stress effects
Solution Approach 2:
The interference between brake and lamination, which initially causes harmful excessive stress, is converted into a beneficial mechanism. The pockets are designed to utilize this interference pressure to compact and hold laminations securely while absorbing the harmful stress components, transforming the problematic interference into a useful packing force
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The brake device maintains constant interference, prevents breakage, reduces sharpening needs, ensures high-quality laminations, and minimizes vibrations and noise in electric machines, while extending the lifespan and reducing production costs.
Implementation Method 1
such an interference of 0.01 mm along the entire perimeter of the round shape (considering the example of the round lamination) generates a force with direction opposite the shearing load and this allows the lamination to remain 'clinging' inside the brake
Implementation Method 2
pockets at stress intensification zones, to maintain constant interference and absorb deformations
Data Source
AI summary
A brake device (10, 10′) for the realization of laminar packages for electrical use defined by the overlapping of magnetic laminations formed by shearing, coupled to a shearing apparatus (13) below a shearing mould (14), with said brake device comprising a brake block (15, 15′), provided with an opening (16, 16′) with a shape corresponding to that of a lamination (12′) and with a size smaller than that of the lamination to define with said lamination an interference (Δ) functional to the packing of the laminations (12) and comprising mechanical stress compensation means adapted to keep said interference (Δ) constant.