Die-Inserted Separating Element for Lamination Stack Reproducibility
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Solution Overview
Problem
Existing methods for separating sheet metal parts in lamination stacks require laborious and non-reproducible application of a separating element, necessitating precise positioning and compensation for deviations in the advancing motion of the electrical steel strip.
Innovation Solution
A method where the separating element, smaller or the same size as the die, is inserted into the die after the first sheet metal part is stamped out and before the second, allowing for reliable and reproducible application between sheet metal parts, facilitated by a conveyor system that moves the separating element into the die, ensuring exact separation and reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separating element is laminated onto the electrical steel strip before stamping, then separation between lamination stacks is achieved, but the application process becomes laborious and requires exact positioning with control loops
Solution Approach 1:
The separating element is inserted into the die cavity before the stamping operation begins. This preliminary positioning eliminates the need for complex control loops during stamping, as the separator is already in place to define the separation plane between lamination stacks.
Solution Approach 2:
The separating element is extracted from the continuous lamination stack by inserting it into the die cavity at specific intervals. This allows the die to stamp out individual sheet metal parts while the separating element remains positioned to enable clean separation between stacks.
2Ease of manufacture
If the separating element is inserted into the die after the first sheet metal part is stamped out, then the application becomes simpler and more reproducible, but the timing and positioning must be precisely controlled
Solution Approach 1:
The separating element is inserted into the die cavity in advance, before the stamping of subsequent sheet metal parts. This preliminary placement ensures that the separator is correctly positioned and will automatically define the separation plane as stamping proceeds, simplifying the overall manufacturing process while maintaining precision.
3Reliability
If the separating element is provided in the form of a flat shim, then the separation function is achieved, but the element may interfere with the stamping process or die operation
Solution Approach 1:
The separating element is nested within the die cavity, fitting into the space already defined by the die geometry. This nesting arrangement ensures the separator performs its separation function while remaining confined to the die cavity and not interfering with the stamping operation or sheet metal parts.
Data Source
AI summary
A device and a method for connecting sheet metal parts to form lamination stacks are demonstrated, in which sheet metal parts are stamped out of an electrical steel strip by means of at least one stamping stage, which has a die and a cutting edge that cooperates with the die, and the stamped-out sheet metal parts are stacked and at least integrally joined to form a plurality of lamination stacks; at least between a first sheet metal part of the stacked sheet metal parts and the subsequent second sheet metal part of the stacked sheet metal parts, a separating element is provided in order to facilitate the separation of the integrally joined sheet metal parts in lamination stacks. In order to improve the reproducibility of the method, when applying the separating element, it is proposed that after the first sheet metal part is stamped out and before the second sheet metal part is stamped out, the separating element which, in accordance with the die geometry, is smaller or of the same size is conveyed to the die, is inserted into said die, and is thus provided to the first sheet metal part.