Laminated Iron Core Bridge Deformation Control
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Solution Overview
Problem
In the manufacturing of laminated iron cores, the deformation of bridge portions between punched holes and the outer peripheral edge leads to reduced magnetic efficiency due to magnetic flux leakage, especially when using progressive dies for blanking, resulting in clearances and deformation of magnet-insert holes.
Innovation Solution
A method involving coining from below to form thinned bridge portions on the outer peripheral portion of the iron core piece, followed by blanking from above or below using a projection portion on the punch, and laminating the iron core pieces to prevent deformation and enhance magnetic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin-wall processing is performed from the upper surface side of the iron core piece to form the bridge portion, then the thickness of the bridge portion is reduced to prevent magnetic flux leakage, but clearances are produced between the punch and the bridge portions during blanking, causing the punch to be disabled to touch the bridge portions and resulting in deformation of the bridge portions outward in the radial direction
Solution Approach 1:
The bridge portion is formed by thin-wall processing before the blanking operation. This preliminary action creates a thinned bridge portion that is more resistant to deformation during subsequent blanking, as the reduced thickness provides better structural control and prevents outward radial deformation that would occur if the bridge portion were formed after blanking.
Solution Approach 2:
The manufacturing process is segmented into distinct operations: first forming the bridge portion through thin-wall processing, then performing blanking separately. This segmentation allows each operation to be optimized independently, ensuring the bridge portion maintains its shape during blanking without interference from punch clearances.
2Loss of energy
If the bridge portions are formed to extend over the outer peripheral edge of the iron core piece and magnet-insert holes, then the magnetic flux leakage is reduced, but such deformation is transmitted to the magnet-insert holes as well, causing similar problems in other punched holes
Solution Approach 1:
The bridge portions are formed by thin-wall processing before punching the magnet-insert holes. This preliminary formation ensures the bridge portions have controlled thickness and shape, preventing deformation from being transmitted to the magnet-insert holes during subsequent punching operations.
Solution Approach 2:
The thin-wall processing is applied locally to the bridge portions only, giving them different (thinner) quality compared to the rest of the iron core piece. This local quality change reduces magnetic flux leakage in the bridge portions while maintaining the structural integrity and shape accuracy of the magnet-insert holes.
3Productivity
If progressive die is used for blanking the iron core piece, then the productivity is improved, but clearances between the punch and bridge portions are produced, disabling the punch to touch the bridge portions and causing deformation
Solution Approach 1:
The bridge portion is formed by thin-wall processing before the progressive die blanking operation. This preliminary action ensures the bridge portion has controlled thickness and shape, making it resistant to deformation even when clearances exist between the punch and bridge portion during high-speed progressive die blanking.
Solution Approach 2:
The thin-wall processing creates a preliminary anti-action by pre-thinning the bridge portion, which counteracts the deforming forces that would otherwise occur during blanking. This pre-prepared structural state prevents the bridge portion from deforming outward in the radial direction during subsequent blanking operations.
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 method effectively prevents deformation of bridge portions during blanking, reduces magnetic flux leakage, and improves the efficiency of the motor by maintaining the specific shape of the iron core piece and supporting the bridge portions during punching, resulting in higher motor efficiency.
Implementation Method 1
coining the thin sheet from below to form a thinned bridge portion on an outer peripheral portion of an iron core piece
Implementation Method 2
blanking the iron core piece from the thin sheet from above or below after forming the bridge portion
Implementation Method 3
laminating the iron core piece on another iron core piece to manufacture the laminated iron core
Data Source
AI summary
In a method for manufacturing a laminated iron core from a thin sheet, the method includes coining the thin sheet from below to form a thinned bridge portion on an outer peripheral portion of an iron core piece, blanking the iron core piece from the thin sheet from above or below after forming the bridge portion, and laminating the iron core piece on another iron core piece to manufacture the laminated iron core.