Electromagnetic Sheet Stack Gripping for Transformer Core Alignment

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Solution Overview

Problem

Existing gripping systems for sheet cores are rigid and unable to compensate for misalignments between pins and holes, leading to jams and damage during the production of electrical energy transmission and distribution transformers, resulting in high processing times and costs due to manual handling and rejection of damaged sheets.

Innovation Solution

A gripping system that uses an electromagnetic field to attract and align stacks of grain-oriented sheets, allowing for automatic handling and positioning on assembly tables, preventing jams and deformations by compensating for alignment errors through a combination of electromagnetic attraction and mechanical support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a rigid gripping system is used to automatically handle stacks of sheets, then automation is improved, but the system cannot compensate for misalignments between pins and holes, leading to jams and sheet damage

Engineering Contradiction:

Improveautomation of stack handlingVSAvoidalignment tolerance

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The gripping system incorporates a flexible gripping element that can dynamically adapt its shape and position to compensate for misalignments between the stack of sheets and the pin. This flexibility allows the system to maintain reliable operation while achieving full automation, resolving the contradiction between automation extent and alignment tolerance.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The gripping element's physical parameters (such as its degree of flexion or position) are changed to match the actual alignment conditions of the stack. By adjusting these parameters in real-time, the system can handle misaligned stacks without jams or damage, enabling both high automation and high reliability.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If manual handling of stacks of sheets is used, then alignment control is improved, but processing time increases and production efficiency decreases

Engineering Contradiction:

Improvealignment controlVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical handling system with an automated electromagnetic gripping system. The gripping element, actuated by a motor, can precisely control the positioning and alignment of the stack of sheets, achieving both high manufacturing precision and high productivity by eliminating manual operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If automated gripping systems are used to move and produce stacks of sheets, then productivity is improved, but the rigid structure causes jams and sheet damage due to inability to compensate misalignments

Engineering Contradiction:

Improveproduction speedVSAvoidjams and sheet damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The gripping system employs a flexible gripping element (such as a thin film or shell structure) that can bend and deform to accommodate misalignments in the stack of sheets. This flexibility prevents jams and sheet damage while maintaining high production speed, as the flexible element can adapt to positional variations without transmitting harmful forces to the sheets.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Enables the automatic production of sheet cores without interruptions, reducing processing times and costs by ensuring accurate alignment and handling of large and heavy sheet stacks, thereby improving production efficiency and reducing sheet damage.

Implementation Method 1

an electromagnetic system (10), configured to produce an electromagnetic field (E) suited to attract the stack of sheets (W)

Methodology Applied

Scientific EffectElectromagnetic field: Electromagnetic Induction

Data Source

PatentEP4111479B1Method for the production of sheet cores, gripping system for stacks of sheets and plant for the production of sheet cores

Publication Date: 2024.12.11 L A E LUGHESE ATTREZZATURE PER LELETTROMECCANICA SRL

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AI summary

Method, gripping system (9) and plant (1) for the production of stacked grain oriented sheet cores (O) for transformers by means of stacks of sheets (W); the method providing for providing a stack of sheets (W) comprising one or more sheets (P) made of grain oriented electrical steel; grabbing said stack of sheets (W) by means of a gripping system (9); placing the stack of sheets (W) on an assembly table (7; 7I; 7II; 7III; 7IV); during the step of placing, the stack of sheets (W) falling in free fall along a path (txl).