3D Laminated Field Pole Construction via Strip Stacking
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Solution Overview
Problem
Existing techniques for constructing three-dimensional field pole structures in electrodynamic machines are costly and result in poor performance due to high tooling costs and material scrap rates, limiting the ability to produce a wide range of shapes and sizes effectively.
Innovation Solution
A method involving a die punching system and a laser-based system that uses lamination strips of varying widths and lengths to construct three-dimensional laminated shapes, with computer-controlled processes to optimize lamination parameters and minimize material waste, allowing for flexible construction of complex shapes with reduced material loss and lower operational forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stamping techniques are used to construct laminated structures for field pole assemblies, then the manufacturing process is well-established and reliable, but the tooling costs and material scrap rates are prohibitive
Solution Approach 1:
The field pole structure is segmented into multiple thin lamination strips that are stacked and bonded together. This segmentation allows for more efficient material utilization compared to traditional stamping, as the strips can be cut to exact dimensions and stacked with minimal waste between layers. The segmented approach enables precise material placement and reduces overall scrap rates while maintaining manufacturing reliability through standardized strip production processes
Solution Approach 2:
The invention transitions from two-dimensional stamping to three-dimensional lamination by stacking multiple thin strips vertically. This dimensional change allows material to be utilized more efficiently across the volume of the field pole structure, reducing surface scrap while maintaining the required structural integrity and magnetic properties through the layered construction approach
2Ease of manufacture
If traditional stamping techniques are used to construct laminated structures for field pole assemblies, then the manufacturing process is well-established, but the tooling costs are prohibitive
Solution Approach 1:
The field pole structure is divided into multiple thin lamination strips that can be manufactured using simpler, more cost-effective processes. Instead of requiring expensive large-format stamping dies, the strips can be produced using less costly cutting and forming methods, then assembled through stacking and bonding. This segmentation reduces tooling costs while maintaining ease of manufacture through standardized assembly procedures
Solution Approach 2:
The lamination strips are prepared in advance with pre-formed edges and surfaces that facilitate efficient stacking and bonding. This preliminary preparation allows for faster assembly and reduces the need for complex tooling during the final assembly process, lowering overall tooling costs while maintaining manufacturing simplicity through modular construction
3Strength
If strip shearing techniques with traditional interlocking parts are used, then the structural integrity is maintained, but the manufacturing cost is high
Solution Approach 1:
The invention replaces traditional mechanical interlocking methods with a bonding system that joins lamination strips together. This substitution eliminates the need for complex interlocking features and associated manufacturing steps, reducing production costs while maintaining structural integrity through the bonding process. The bonding approach allows for simpler, more cost-effective manufacturing of the field pole structure
4Productivity
If continuous bar production techniques are used, then the manufacturing efficiency is improved, but the ability to produce varied shapes is limited
Solution Approach 1:
The lamination strip production system is designed to be dynamic and adaptable, allowing for rapid changes in strip dimensions, widths, and lengths to accommodate different field pole shapes. This dynamic capability enables continuous, efficient production while maintaining the versatility to produce a wide range of shapes and sizes, resolving the contradiction between manufacturing efficiency and shape variety
5Manufacturing precision
If precision dies are used for stamping, then the manufacturing precision is improved, but the cost increases significantly
Solution Approach 1:
The field pole structure is divided into multiple thin lamination strips that can be manufactured with standard precision cutting methods. This segmentation eliminates the need for expensive high-precision stamping dies, as each strip can be cut to the required dimensions using more cost-effective methods. The cumulative precision of multiple strips achieves the required overall dimensional accuracy without requiring expensive single-step precision forming
Data Source
AI summary
A method for constructing a three-dimensional laminated shape includes selecting a first lamination strip from a plurality of lamination strips with different widths assembled on a spool. The first lamination strip is stacked on a stacking device and is cut at a first lamination length. A second lamination strip is selected from the spool. The second lamination strip is stacked and cut at a second lamination length different than the first lamination length. The process is repeated to construct a three-dimensional laminated shape of an electrodynamic device. In another embodiment, a computer readable storage medium includes executable instructions to collect design information characterizing a three-dimensional laminated shape and compute lamination parameters based on the design information. The computer readable storage medium further includes executable instructions to direct a plurality of components to construct a three-dimensional laminated shape of an electrodynamic device based on the lamination parameters. The three-dimensional laminated shape comprises a plurality of lamination strips of different lamination widths and different lamination lengths.