Hexagonal Stator Lamination Segmentation for Scrap Reduction
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Solution Overview
Problem
Current methods for manufacturing large rotor/stator laminations result in significant material scrap and lower quality due to the need for segmented production and complex assembly processes, particularly for larger stators and rotors.
Innovation Solution
A method involving slitting electrical steel into a material strip with a width corresponding to half the outer diameter, making slant cuts to form trapezoids, joining them to create hexagons, and then stamping the laminations, which reduces material waste and simplifies assembly by using fewer segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If material is slit and sheared into multiple segments to produce large stator laminations, then the lamination can be produced in standard equipment, but material scrap increases significantly
Solution Approach 1:
The patent applies segmentation by dividing the large stator lamination into multiple segments that can be produced in standard equipment. The key innovation is using a hexagonal geometry where segments are arranged to minimize scrap while maintaining manufacturability in conventional presses with limited stroke capacity.
Solution Approach 2:
The patent transitions from traditional rectangular segment layouts to a hexagonal geometric arrangement. This dimensional change in the overall lamination shape allows for more efficient material utilization and reduced scrap when cutting segments from the parent material.
2Ease of manufacture
If multiple lamination segments are assembled and welded to form large stators, then production can proceed with available equipment, but assembly complexity and labor increase
Solution Approach 1:
The stator is divided into multiple segments that can be manufactured separately in standard equipment with limited stroke capacity. These segments are then assembled and welded together to form the complete large stator lamination, enabling production beyond equipment limitations.
Solution Approach 2:
The patent creates a universal assembly process that can handle different stator sizes and configurations using the same segment assembly and welding methodology. The hexagonal segment design provides a standardized interface that simplifies the assembly process across various applications.
3Manufacturing precision
If rotor slots are added after punching the rotor blank, then slot precision can be achieved, but the number of processing steps increases
Solution Approach 1:
The rotor slots are punched into the rotor blank before the final assembly and welding operations. This preliminary action ensures that slots are precisely positioned and formed early in the process, allowing subsequent operations to proceed without interference and maintaining high precision.
Solution Approach 2:
The patent combines multiple operations including blank punching, slot punching, and assembly into an integrated workflow. By performing slot punching while the rotor blank is still accessible and in a stable state, the process reduces the total number of separate processing steps while maintaining precision.
4Loss of substance
If electrical steel is slit to exact width requirements for each component, then material utilization improves, but the number of slitting operations and setup changes increases
Solution Approach 1:
The patent uses a universal parent material size that can serve multiple purposes - producing both stator and rotor segments, and accommodating different lamination sizes. This reduces the need for frequent slitting operation changes while maintaining good material utilization through the hexagonal segment layout.
Solution Approach 2:
The patent changes the geometric parameters of the lamination from traditional rectangular shapes to hexagonal shapes. This parameter change allows for more flexible material utilization and reduces the impact of fixed slitting widths, as the hexagonal geometry can be efficiently cut from various parent material sizes with less waste.
Data Source
AI summary
In a method for manufacturing a lamination for a motor or generator where a plurality of the laminations are used to form a core of the motor or generator, a material strip of electrical steel is provided having a width substantially corresponding to half of an outer diameter of the lamination to be created. Slant cuts are made along the material strip to form trapezoids of substantially a same area. Two of the trapezoids are joined together along a side edge of each to form a hexagon. The lamination is then stamped from the hexagon.