Ferromagnetic Core Lamination Gluing With Printed Adhesive Transfer
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Solution Overview
Problem
Existing methods for manufacturing ferromagnetic cores of electric machines by gluing laminations together face challenges such as uneven adhesive application, spillage, and health hazards due to the use of harmful materials, leading to functionality and quality issues.
Innovation Solution
A plant and method that utilize a printing device with a transfer element to apply adhesive material precisely according to lamination outlines, absorbing irregularities and preventing overflow, combined with a controlled application of activating compounds to ensure uniformity and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spraying techniques are used to apply adhesive material, then the adhesive can be applied to the metal laminate, but the adhesive material cannot reach certain areas, causes superimpositions or affects areas outside the contour
Solution Approach 1:
A transfer element (such as a roller or belt) is introduced as an intermediary between the adhesive application system and the metal laminate. The transfer element receives the adhesive material and transfers it to the laminate surface, ensuring precise delivery to target areas while preventing overflow and contamination of non-target areas.
Solution Approach 2:
The transfer element is configured to replicate the contour of the metal laminate, creating a precise copy of the laminate's surface geometry. This allows the adhesive to be applied exactly where needed, following the laminate's shape and avoiding areas outside the contour.
2Ease of manufacture
If adhesive material is applied without well-defined impressions, then the application process is simpler, but the adhesive distribution is non-uniform and can overflow from the ferromagnetic core
Solution Approach 1:
The transfer element is pre-configured with well-defined impressions or patterns that correspond to the desired adhesive application areas. These impressions are created beforehand on the transfer element, so when adhesive is applied, it is automatically deposited in the correct locations with uniform distribution, preventing overflow.
Solution Approach 2:
The transfer element provides different properties to different areas of the adhesive application process. Areas where adhesive should be applied have corresponding impressions on the transfer element, while areas where adhesive should not be applied have no impressions, creating local quality variations in adhesive distribution.
3Productivity
If adhesive material is applied to the continuous metal laminate, then the laminations can be joined together, but the harmful adhesive materials pose health risks to operators
Solution Approach 1:
The adhesive application process is enclosed in a controlled environment that isolates operators from harmful adhesive materials. This may include sealed chambers, local exhaust ventilation, or inert atmosphere creation that prevents harmful substances from reaching operators while allowing the manufacturing process to continue.
Solution Approach 2:
The transfer element system allows for precise adhesive application, which reduces overall adhesive usage. By delivering adhesive only where needed through the transfer element's impressions, less adhesive is required, thereby reducing the amount of harmful material in the environment and minimizing health risks to operators.
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 solution ensures precise, repeatable, and uniform adhesive application, preventing spillage and maximizing coverage while protecting equipment and ensuring operator safety, resulting in high-quality ferromagnetic cores with improved manufacturing efficiency.
Implementation Method 1
The plant (10) comprises at least one unit (21) for applying an adhesive material to a surface of the continuous metal laminate (11)
Implementation Method 2
absorbing irregularities and preventing overflow
Data Source
Figure 1A~1B
Figure 2
Figure 3~5
AI summary
A plant (10) and a method are described for manufacturing ferromagnetic cores of electric machines formed by a plurality of laminations which are packed and joined together by gluing in a blanking/punching tool (15) to which a continuous metal laminate (11) of ferromagnetic material is fed. In addition to the blanking/ punching tool, the plant comprises at least one unit (21) for applying an adhesive material to a surface of the continuous metal laminate, at least one unit (25) for applying an activating compound to the opposite surface of the continuous metal laminate and at least one control unit (22) for controlling the application of the adhesive material and the activating compound into the respective application units. The unit for applying an adhesive material to a surface of the continuous metal laminate comprises a printing device (23, 60) and at least one transfer element (28, 51) on which the printing device deposits the adhesive material according to one or more impressions of a shape corresponding to the outline of each of the laminations. The adhesive material is then applied by the at least one transfer element to a surface of the continuous metal laminate according to the outline of each lamination, which is defined by the impressions.