Insulating Sheet Forming via Two-Stage Mold and Inclined Guide
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Solution Overview
Problem
The existing methods for forming insulating sheets for rotary electric machines require multiple steps and increased process time due to the need to form folds in the sheets, which complicates the shaping process.
Innovation Solution
A sheet-like member forming method and apparatus that involves pushing the sheet into a first concave mold to form a first shape and then into a second mold with an inclined surface, allowing the sheet to be formed into a predetermined shape without folds, thereby reducing the number of steps and process time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a fold is formed in the connecting leg portion and the insulating plate portion, then the insulating sheet can be deformed into a predetermined shape, but the number of steps increases and the process time also increases
Solution Approach 1:
The forming process is divided into two sequential operations: first forming a preliminary shape with a first mold, then forming the final predetermined shape with a second mold. This segmentation allows each mold to perform a specific function, eliminating the need for separate fold-forming steps while achieving the desired complex shape efficiently
Solution Approach 2:
The second mold is designed with an inclined surface that allows the insulating sheet to be pushed from a preliminary shape to a final shape in a different directional dimension. This dimensional approach enables shape transformation without requiring additional folding operations, reducing process steps while maintaining shape complexity
2Force
If the second mold portion is formed to be inclined so that the width becomes narrower from upstream side to downstream side, then the sheet-like member can be formed with narrower width without applying large force, but the mold design becomes more complex
Solution Approach 1:
The second mold portion incorporates an inclined surface with a gradual width reduction from upstream to downstream side. This curved/angled geometry allows the material to be progressively compressed and shaped, distributing the forming force along the incline rather than applying concentrated force, thereby reducing the maximum force required while achieving the narrower final width
3Ease of manufacture
If the second mold portion includes a guide portion to guide one end portion of the sheet-like member, then the sheet-like member can be easily formed into overlapping shape, but the mold structure becomes more complex
Solution Approach 1:
A guide portion is incorporated into the second mold structure that acts as an intermediary element to direct and position the insulating sheet during the forming process. This guide feature ensures proper alignment and overlap of sheet portions, making the formation of the overlapping shape straightforward while the added structural element remains integrated into the mold design
Data Source
AI summary
An insulating sheet is pushed into a first mold portion, and formed in a first shape along a shape of the first mold portion. The insulating sheet of the first shape inside the first mold portion is pushed into the second mold, and is deformed by a front mold portion, a front guide portion, and a bent convex portion of the front mold, and a rear mold portion and a rear guide portion of the rear mold, and is formed in a second shape. The insulating sheet of the second shape is inclined such that the front end portion overlaps the rear end portion in a first direction, and the width in a front-rear direction becomes narrower toward the front and the rear end portions. The insulating sheet inserted in the second mold and formed in the second shape is inserted into a slot of a stator core.