Electromagnetic Sheet Stack Gripping for Jam-Free Core Assembly

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Solution Overview

Problem

Existing gripping systems for handling grain oriented electrical steel sheets in the production of sheet cores are rigid and unable to compensate for misalignments, leading to jams and damage, resulting in high processing times and costs due to sheet rejection.

Innovation Solution

A gripping system utilizing an electromagnetic field to attract and align stacks of sheets, combined with a support system to ensure precise placement on assembly tables, preventing misalignment and deformation during transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid gripping system is used to handle stacks of sheets, then the gripping system provides stable and strong holding force, but it cannot compensate for misalignments between pins and holes, leading to jams and sheet damage

Engineering Contradiction:

Improvestable holding forceVSAvoidability to compensate for misalignments

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent employs flexible elements (such as elastic fingers or compliant mechanisms) in the gripping system that can deform to accommodate misalignments between the stack of sheets and the assembly table pins. These flexible components maintain a secure grip while adapting to position variations, preventing jams and damage to the sheets.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The gripping system incorporates dynamic elements that can adjust their position or orientation during the transfer operation. This allows the system to adapt to misalignments in real-time, maintaining reliable sheet handling while compensating for positioning errors between the stack and the assembly table.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If manual operations are used for transfer and positioning of stacks of sheets, then the system can handle misalignments with operator judgment, but it requires high processing times and dedicated operators

Engineering Contradiction:

Improveability to handle misalignmentsVSAvoidprocessing time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical operations with an automated gripping system that incorporates sensors and control mechanisms. This system can detect misalignments and automatically adjust its operation to handle the stacks of sheets, eliminating the need for dedicated operators while maintaining the ability to compensate for positioning errors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated gripping system includes feedback mechanisms (such as sensors or vision systems) that detect the position of the stack of sheets relative to the assembly table pins. This feedback information is used to adjust the gripping system's positioning or orientation, enabling automatic compensation for misalignments without requiring manual intervention.

Inventive Principle:

Principle #23Feedback

3Productivity

If automated gripping systems are used to move and produce stacks of sheets, then processing time is reduced, but the rigid systems cause jams and sheet damage due to inability to compensate for misalignments

Engineering Contradiction:

Improveprocessing speedVSAvoidjams and sheet damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The automated gripping system incorporates flexible elements that can deform to accommodate misalignments during the transfer operation. These compliant components maintain a secure grip on the stack of sheets while adapting to position variations, preventing jams and damage that would otherwise occur with rigid gripping mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The gripping system includes cushioning or damping elements that absorb shocks and minor misalignments during the transfer operation. This beforehand cushioning protects the sheets from damage and prevents jams by accommodating positioning errors before they can cause harmful effects.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 automatic production of sheet cores without jams or interruptions, ensuring accurate alignment and handling of large and heavy sheets, reducing production downtime and costs.

Implementation Method 1

a gripping system (9), configured to grab a stack of sheets (W)

Methodology Applied

Scientific EffectElectromagnetic field: Electromagnetic Induction

Data Source

PatentUS12406803B2Method for the production of sheet cores, gripping system for stacks of sheets and plant for the production of sheet cores

Publication Date: 2025.09.02 L A E LUGHESE ATTREZZATURE PER LELETTROMECCANICA SRL

AI summary

Method, gripping system and plant for the production of stacked grain oriented sheet cores for transformers by means of stacks of sheets; the method providing for providing a stack of sheets comprising one or more sheets made of grain oriented electrical steel; grabbing said stack of sheets by means of a gripping system; placing the stack of sheets on an assembly table; during the step of placing, the stack of sheets falling in free fall along a path.