Cull Plate Runner Design for Laminated Iron Core Resin Sealing
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Solution Overview
Problem
The existing methods for manufacturing laminated iron cores with resin sealing require frequent changes in molding dies and dummy plates, leading to increased labor, downtime, and productivity losses due to resin residue issues, especially when dealing with multiple types of laminated iron cores.
Innovation Solution
A method involving a cull plate with a groove-shaped runner and a through hole, allowing for resin injection without changing the molding die, where the cull plate is designed with a gate hole and a through hole at different positions to facilitate easy removal of resin residue without breaking the runner parts, enabling continuous production without stopping the line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a dummy plate is used to seal multiple kinds of laminated iron cores with resin in one molding die, then adaptability is improved, but device complexity increases due to complicated runner shapes
Solution Approach 1:
The dummy plate is segmented into a first dummy plate with runners and a second dummy plate with gate holes, allowing the resin injection system to be divided into separate functional components that can be independently designed and maintained
Solution Approach 2:
The first dummy plate acts as an intermediary component between the resin reservoir and the second dummy plate, guiding resin through runners to the gate holes while preventing direct contact between resin and the laminated iron core body
2Adaptability or versatility
If resin runners are made long to reach gate holes in various positions, then adaptability is improved, but reliability deteriorates due to runner breakage
Solution Approach 1:
The dummy plate system is segmented into two separate plates, allowing the runners to be contained in the first dummy plate while gate holes are in the second dummy plate, reducing the risk of runner breakage during resin removal
Solution Approach 2:
The resin removal operation is extracted as a separate step performed on the first dummy plate after production, allowing runners to be cleaned without affecting the second dummy plate or the laminated iron core body
3Manufacturing precision
If resin residue removal is performed frequently to maintain production quality, then manufacturing precision is improved, but productivity deteriorates due to production line stoppage
Solution Approach 1:
The first dummy plate serves as an intermediary that accumulates resin residue in its runners, allowing removal operations to be performed on this separate component without stopping the production line or affecting the second dummy plate
Solution Approach 2:
The first dummy plate is designed to be temporarily removed, cleaned of resin residue, and returned to production, allowing continuous operation while maintaining manufacturing precision through periodic maintenance of the resin delivery system
4Device complexity
If a single dummy plate design is used for all laminated iron core types, then device complexity is reduced, but adaptability deteriorates due to inability to accommodate different magnet-insert hole configurations
Solution Approach 1:
The dummy plate is divided into two separate plates, each optimized for specific functions: the first dummy plate for resin delivery and the second dummy plate for gate hole positioning, allowing independent design of each component
Solution Approach 2:
The first dummy plate with standardized runners can be used universally across different laminated iron core types, while the second dummy plate is configured specifically for each core type's magnet-insert hole pattern, combining universal and customized elements
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
This configuration allows for efficient removal of resin residue from the cull plate, preventing runner breakage and enabling the cull plate's repeated use, thus maintaining production continuity and reducing labor and downtime.
Implementation Method 1
a permanent magnet 72 is inserted into each of a plurality of magnet-insert holes 71 provided in a laminated iron core 70 and heated at a prescribed temperature
Data Source
AI summary
A method for manufacturing a laminated iron core is provided. A laminated iron core body including a permanent magnet inserted into a magnet-insert hole is arranged between a molding die and a holding die. A cull plate is arranged between the molding die and the laminated iron core body. The cull plate has a groove shaped runner directed toward the magnet-insert hole from a resin reservoir and provided with a gate hole communicating with the magnet-insert hole, and a through hole which vertically passes through the cull plate is formed in the runner of the cull plate at a different position from a position of the gate hole. After the magnet-insert hole is filled with the mold resin a resin residue remaining in the cull plate is pushed off and removed from the gate hole and the through hole.