Laminated Iron Core Ejection Detection for Press-Fit Hole Anomalies
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Solution Overview
Problem
The existing methods for manufacturing laminated iron cores face disruptions due to damage to punches forming press-fit holes, leading to improper formation of press-fit holes and tabs, which can cause the laminated iron cores to be stuck inside the die, resulting in production inefficiencies.
Innovation Solution
An apparatus and method that include a press device with a tab forming unit, a press-fit hole forming unit, and a punching unit, along with a detecting unit to control the operation and detect anomalies, ensuring proper ejection of laminated iron core pieces by forming tabs and press-fit holes selectively and monitoring the ejection process to prevent anomalies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If punches are used to form press-fit holes by punching out tabs, then press-fit holes are formed in the workpiece, but the punches may become damaged and fail to form press-fit holes properly
Solution Approach 1:
A detection device detects whether a laminated body is properly ejected from the die. When ejection fails (indicating possible punch damage or tab formation issues), the system generates a detection result that triggers an alarm or stops operation, preventing defective products and enabling timely maintenance of the punches
Solution Approach 2:
The detection device acts as an intermediary between the punching process and the control system. It monitors the ejection status and translates physical ejection behavior into detection results that can be used to infer punch condition and trigger appropriate responses
2Ease of manufacture
If tabs are formed in all iron core pieces, then tabs are available for joining, but the laminated iron cores cannot be ejected from the die when press-fit holes are not formed
Solution Approach 1:
Tabs are formed in all iron core pieces uniformly, but their function varies locally: in pieces designated for press-fit holes, tabs are punched out to create holes, while in other pieces tabs remain for joining. This local differentiation in tab functionality allows both joining capability and proper ejection behavior
Solution Approach 2:
Instead of forming tabs selectively only where needed, the invention forms tabs in all pieces and then selectively removes them where press-fit holes are required. This inverted approach simplifies the forming process while maintaining the ability to create both joining tabs and press-fit holes
3Productivity
If the press device operates continuously without detection, then production efficiency is maintained, but anomalies go undetected causing disruptions
Solution Approach 1:
The detection device provides continuous feedback on ejection status during production. When an anomaly is detected (failure to eject), the system can alert operators or automatically stop, preventing disruptions while allowing continuous operation during normal conditions
Solution Approach 2:
The system monitors its own operation through the detection device that automatically detects ejection failures without external intervention. The press device essentially self-diagnoses potential problems through the ejection detection mechanism
Data Source
AI summary
An apparatus for manufacturing a laminated iron core includes a press device, circuitry, and a detecting unit. The press device includes a tab forming unit, a press-fit hole forming unit, and a punching unit. The punching unit is configured to use a die and a punch to punch out, from the workpiece, iron core pieces including press-fit holes and iron core pieces including tabs, stack the iron core pieces in the die to form a laminated body, and eject the laminated body through an ejection port. The detecting unit is configured to detect ejection of the laminated body through the ejection port. The circuitry is configured to determine that there is an anomaly in the press-fit hole forming unit when the detecting unit does not detect ejection of the laminated body within a predetermined detection time.