Electric Machine Core Element Punching With Product-Shaped Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing core elements for rotary electric machines face challenges in maintaining positioning accuracy and material yield rates due to the stiffness of electromagnetic steel sheets, leading to issues like twist, torsion, and reduced high-speed conveyance and cutting capabilities, particularly when using pilot pins for positioning.
Innovation Solution
A method involving a press mechanism with a feeding device for punch cutting out core elements from a belt-like electromagnetic steel sheet, utilizing product-shaped pilots based on the punch cut-out trace shapes of previously cut core elements to ensure precise positioning and high-speed cutting without reducing material yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pilot pins are used for positioning the electromagnetic steel sheet, then positioning accuracy in the forward feeding direction is improved, but the steel sheet experiences twist or torsion when its stiffness is insufficient
Solution Approach 1:
A support plate is introduced as an intermediary between the pilot pins and the electromagnetic steel sheet. The support plate has a larger area than the pilot pins, distributing the positioning force over a wider region. This reduces localized stress and prevents the steel sheet from twisting or torsioning while maintaining positioning accuracy in the forward feeding direction.
2Device complexity
If pilot pins are disposed only at end portions of the steel sheet, then the apparatus structure is simplified, but high speed conveyance and high speed punch cutting out cannot be conducted
Solution Approach 1:
The positioning system is segmented into multiple support plates distributed across the steel sheet, rather than relying on a single centralized positioning mechanism. Each support plate handles a localized region, allowing the system to maintain simplicity while achieving stable high-speed conveyance and punch cutting out through distributed support.
3Loss of substance
If pilot pins and punch cutting out portion are closely disposed to improve material yield rate, then material utilization is improved, but the die of core element suffers breakage
Solution Approach 1:
The support plate is positioned in advance at the location where pilot pins would normally be placed. This preliminary positioning structure provides pre-support to the steel sheet before the punch cutting operation begins, preventing excessive stress concentration that would otherwise occur when pilot pins are closely disposed near the punch cutting portion. This allows material yield rate to be improved without causing die breakage.
4Adaptability or versatility
If multiple punch cutting out processes are used to cut one product shape, then complex product shapes can be achieved, but variations in positioning dimension with pilot pins deteriorate dimensional accuracy
Solution Approach 1:
The support plate serves multiple functions: it provides positioning support, distributes stress, and maintains dimensional stability across multiple punch cutting operations. By using this universal support structure, the system can handle complex product shapes requiring multiple cutting processes while maintaining consistent dimensional accuracy throughout all operations.
Data Source
AI summary
In a method for manufacturing a core element which is used for a divisional layer stack core of a rotary electric machine, the method includes: a first punch cutting out process for punch cutting out a first core element having a product shape, from a belt like electromagnetic steel sheet, with a press mechanism which has a feeding device of the electromagnetic steel sheet, a feeding process for feeding the electromagnetic steel sheet, with the feeding device, and a second punch cutting out process for positioning with a product shaped pilot which has an external shape of the core element, using a punch cut out trace shape of the first core element, and producing a second core element having the product shape, by punch cutting out with the press mechanism.