Lubricant-Free Insulating Sheet Shaping Apparatus
Solution Overview
Problem
The use of lubricants in shaping machines for creating pre-shaped insulating sheets for stators and rotors leads to contamination, complicates machine development and maintenance, and poses environmental and health hazards due to toxic fumes and vapors.
Innovation Solution
An apparatus that folds and cuts insulating strips into pre-shaped sheets without lubricants, using a support structure with rotating and motorized storage drums, shaping elements, and heating devices to form stable S- or Z-shaped cross sections, ensuring the sheets are free from contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lubricating means are provided in shaping machines to reduce friction during folding, then the folding operation becomes easier and more efficient, but the insulating strip becomes contaminated with lubricant and unwanted particles
Solution Approach 1:
The invention extracts and removes the lubricating means from the shaping machine system. By eliminating the lubricant supply mechanism, the patent prevents contamination of the insulating strip while maintaining the folding operation through alternative means (heating and mechanical pressure).
Solution Approach 2:
The invention replaces the mechanical lubrication system with a thermal processing system. Instead of using lubricant to reduce friction during folding, the patent applies heat to the strip and uses controlled mechanical pressure to achieve the folding operation without contamination.
2Ease of operation
If lubricating means are provided in shaping machines, then friction is reduced during the folding process, but the machine development, management and maintenance become more complex
Solution Approach 1:
The invention removes the lubricating means from the shaping machine, thereby eliminating the complexity associated with lubricant storage, dosing, and maintenance. The simplified machine structure reduces development and maintenance requirements while maintaining folding capability through thermal and mechanical means.
3Ease of operation
If lubricating means are provided in shaping machines, then folding operation is facilitated, but toxic or polluting fumes are released due to heating of the lubricant
Solution Approach 1:
The invention extracts and eliminates the lubricant from the system. By removing the lubricating means, the patent prevents the generation of toxic fumes and pollution that would result from heating lubricant during the shaping process, while still achieving the folding operation through alternative methods.
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
The apparatus produces pre-shaped insulating sheets with stable, complex cross-sections without lubricant contamination, simplifying the manufacturing process and reducing environmental and health risks.
Implementation Method 1
heaters, capable of performing one or more operations for folding the strip
Data Source
Figure 1~3
Figure 4
Figure 5~6
AI summary
Apparatus (30) for making pre-shaped insulating sheets (10) for use in a stator or in a rotor comprising shaping elements (40-44) such to produce, starting from a continuous strip (15) made of electrically insulating material having a flat or substantially flat cross section, a strip portion having a cross section comprising a central septum (20) and two lateral portions (21-23, 21' -23' ) joined to a respective end portion of the central septum (20), each of the lateral portions comprising a first section (21,21') joined to the central septum (20), a second section (22,22') joined and perpendicular, or essentially perpendicular, to the first section (21,21'), a third section (23, 23') joined to the second section (22,22') and inclined with respect to the latter towards the central septum (20). The apparatus (30) further comprises a pair of opposite rollers (46,47) having a transverse shaping profile comprising a projecting appendage (56, 57) suitable to be interfaced having a respective portion of the strip (15) facing the central septum (20) and operatively interposable between the central septum (20) and the third inclined section (23,23').