Electromechanical Cam Drive for Magnetic Core Lamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing actuation systems in machines for manufacturing magnetic core laminations, such as hydraulic and pneumatic systems, suffer from noise, vibration, wear, misalignment, and maintenance issues, leading to costly downtime and reduced accuracy.
Innovation Solution
The implementation of an electromechanical cam drive system using electric actuators and cam shafts with linkage members to precisely control the folding and cutting of magnetic strip material, providing accurate and reliable actuation without the drawbacks of hydraulic or pneumatic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic actuators are used for folding and cutting operations, then force capability and system stiffness are improved, but noise, vibration, wear, and maintenance requirements increase
Solution Approach 1:
The patent replaces the hydraulic actuation system with an electric motor-driven cam mechanism. The electric motor (202) drives a cam shaft (204) that converts rotational motion into the reciprocating linear motion required for folding and cutting operations, eliminating hydraulic fluid, pumps, and associated maintenance issues while maintaining sufficient force capability through the mechanical advantage of the cam and linkage system
Solution Approach 2:
The patent explicitly abandons hydraulic actuation in favor of an electromechanical system. The invention description states that hydraulic actuators were previously used but were replaced due to noise, vibration, and maintenance requirements, with the new system using electric motors and mechanical cam mechanisms to achieve the required actuation
2Ease of operation
If pneumatic actuators are used for folding and cutting operations, then ease of operation is improved, but positional accuracy and control between mechanical stops deteriorate
Solution Approach 1:
The patent replaces pneumatic actuators with an electric motor-driven cam mechanism. The cam profile on the cam shaft is precisely engineered to provide accurate positional control throughout the stroke, eliminating the compressibility issues of pneumatic systems while maintaining ease of operation through electric motor control
Solution Approach 2:
The patent uses a dynamically designed cam mechanism where the cam profile is specifically shaped to provide controlled motion throughout the stroke. This allows for variable velocity and acceleration profiles that optimize both ease of operation and positional accuracy, with the cam geometry determining the exact motion characteristics
3Force
If hydraulic actuators are used for folding and cutting operations, then force capability is improved, but noise and vibration increase
Solution Approach 1:
The patent replaces hydraulic actuators with electric motor-driven cam mechanisms, eliminating hydraulic fluid pressure fluctuations and component chatter that generate noise and vibration. The electric motor provides smooth, controlled force delivery while the cam mechanism translates this into precise mechanical motion with minimal vibration
Solution Approach 2:
The patent converts the potential harm of high force requirements into a benefit by using a mechanically optimized cam and linkage system. The cam profile is designed to deliver maximum force at critical points in the cycle while maintaining smooth operation, turning the challenge of high force requirements into an opportunity for precise mechanical design that reduces noise and vibration
4Stress or pressure
If hydraulic actuators are used for folding and cutting operations, then system stiffness is improved, but space requirements and device complexity increase
Solution Approach 1:
The patent replaces the complex hydraulic system with a compact electromechanical cam mechanism. The electric motor, cam shaft, and linkage components occupy significantly less space than hydraulic pumps, fluid reservoirs, filters, and piping. The mechanical cam system inherently provides the required stiffness through rigid component design without requiring additional hydraulic support 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 solution enhances the accuracy and reliability of the folding and cutting process, reducing wear and maintenance needs, and minimizing downtime, while maintaining high positional control and repeatability.
Implementation Method 1
a first cam shaft driven by the first electric actuator and coupled to the folder platen assembly by a first linkage member, the first cam shaft rotatable about a first axis; and a second cam shaft driven by the second electric actuator and coupled to the guillotine platen assembly by a second linkage member
Data Source
AI summary
A machine (10) for manufacturing stackable laminations (4) for a magnetic core (6) is disclosed. The laminations are formed from a magnetic strip material (2). The machine (10) includes a first electromechanical cam drive for actuating a folder that folds the strip material (2) and a second electromechanical cam drive for actuating a cutter that cuts the strip material (2). The folder and the cutter are independently drivable between an uppermost position and a lowermost position. The folder may include a folder platen (130) having an associated folder bar (150) to fold said strip material (2). The cutter may include a guillotine platen (230) having an associated upper cutting blade (245) that cooperates with a fixed lower blade (255) for cutting said strip material (2). The electromechanical cam drive may include any suitable electric actuator (100,200) such as an electric motor.