Laminated Iron Core Stacking With Dummy Blocks for Machining Errors
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Solution Overview
Problem
In the manufacturing of laminated iron cores for rotating electric machines, there is a challenge in ensuring that all iron core pieces are machined correctly, as improper switching of punch states can lead to incomplete or incorrect machining, resulting in core pieces with shapes different from the desired form.
Innovation Solution
A method is introduced where multiple types of machining are performed on designated portions of the workpiece, with a system to determine if standard machining has been done, and if not, a dummy block is formed with a different stacking height to distinguish it from correctly machined core piece blocks, preventing incorrect incorporation into the final laminated iron core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple types of punches are used to selectively machine through-holes in iron core pieces, then the desired shape and cooling passages can be formed, but machining errors occur when punch state switching is improper
Solution Approach 1:
The patent applies preliminary action by forming a dummy block before final assembly to detect and prevent inclusion of incorrectly machined iron core pieces. The dummy block is created by stacking iron core pieces with abnormal shapes (missing through-holes or extra machining) in a separate location, allowing quality verification before the improperly machined pieces are accidentally incorporated into the final laminated iron core assembly.
Solution Approach 2:
The patent uses an intermediary approach by introducing a dummy block as a mediator between the machining process and final assembly. This dummy block serves as a test specimen that intercepts and identifies defective iron core pieces, preventing them from reaching the final product. The dummy block acts as a buffer that allows verification of machining quality without compromising the final assembly.
2Stability of the object's composition
If all iron core pieces are stacked to the same height, then uniform assembly is achieved, but incorrectly machined pieces cannot be distinguished and may be incorporated by mistake
Solution Approach 1:
The patent applies local quality by creating a special location (dummy block formation location) distinct from the normal assembly location. Iron core pieces with abnormal shapes are stacked at this specific location to form a dummy block, while correctly machined pieces are stacked at the normal assembly location. This spatial differentiation allows the system to maintain uniform assembly at the normal location while isolating and identifying defective pieces at the dummy block location.
Solution Approach 2:
The patent segments the stacking process into two distinct functions: normal assembly stacking and dummy block stacking. By separating these functions into different locations and purposes, the system can maintain uniformity for quality assembly while simultaneously creating a quality control mechanism through the dummy block. The segmentation allows independent handling of correctly and incorrectly machined pieces.
Data Source
AI summary
A method for manufacturing a laminated iron core includes sequentially performing multiple types of machining on designated portions of a workpiece from which iron core pieces are to be punched out, determining whether standard machining has been performed on each designated portion, forming core piece blocks by stacking the iron core pieces to have a specified stacking height, and forming, when it is determined that the standard machining has not been performed on any of the designated portions through the determining whether standard machining has been performed, a dummy block by stacking the iron core pieces that include the iron core piece formed by punching out the designated portion not having been subjected to the standard machining, the formed dummy block having a stacking height different from the specified stacking height.