Laminated Iron Core Heating Sequence to Limit Annealing Deformation
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Solution Overview
Problem
Existing methods for annealing laminated iron cores result in deformation due to thermal expansion, as the inner and outer peripheral portions are heated simultaneously, lacking an escape path for deformation.
Innovation Solution
The method involves arranging multiple heating units around the laminated iron core's circumference and controlling their operation to heat regions at different timings, creating heated and unheated areas to absorb thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the entire inner peripheral portion of the laminated iron core is heated substantially at the same time, then heating efficiency is improved, but deformation such as warpage or undulation occurs due to thermal expansion
Solution Approach 1:
The heating process is segmented into multiple stages with different heating zones. Initially, only a first heating zone is activated while a second heating zone remains inactive, allowing controlled thermal expansion in specific regions. This segmentation prevents simultaneous heating of the entire inner peripheral portion, thereby avoiding warpage and undulation while maintaining heating efficiency.
2Manufacturing precision
If multiple heating units are arranged to heat different regions, then deformation is reduced, but device complexity increases
Solution Approach 1:
The heating device is divided into multiple independent heating units arranged around the laminated iron core, with each unit capable of being controlled independently. This segmentation allows selective activation of heating zones to prevent deformation while managing complexity through modular design where each unit performs a specific function.
Solution Approach 2:
The heating system employs dynamic control where heating units are activated and deactivated in sequence based on the heating stage. The control unit dynamically adjusts which heating zones are active, transitioning from heating only the inner peripheral portion to subsequent heating of other portions, thereby reducing deformation while maintaining manageable system complexity through adaptive operation.
3Manufacturing precision
If the heating process is performed in multiple stages with switching heating units, then deformation is reduced, but heating time increases
Solution Approach 1:
The heating process is divided into multiple stages with different heating zones activated in sequence. The first heating zone is activated initially to heat the inner peripheral portion, followed by activation of the second heating zone to heat other portions. This segmented approach reduces deformation while minimizing total heating time by efficiently managing the sequence and duration of each heating stage.
Solution Approach 2:
The heating process employs periodic action with distinct heating stages. The control unit activates and deactivates heating units in a periodic manner, switching between different heating zones at predetermined intervals. This periodic heating pattern allows the laminated iron core to undergo controlled thermal expansion and relaxation, reducing deformation while maintaining reasonable heating time through optimized cycle timing.
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 approach reduces deformation in the laminated iron core by providing an escape path for thermal expansion, ensuring the core is heated effectively without excessive distortion.
Implementation Method 1
heating N regions of the laminated iron core that face the N heating units with the N heating units
Implementation Method 2
the inner peripheral portion tends to thermally expand outward in a radial direction
Data Source
AI summary
A method for manufacturing a laminated iron core includes: arranging N heating units in the laminated iron core such that the N heating units are aligned in a circumferential direction of the laminated iron core, where N is a natural number of two or more; and heating N regions of the laminated iron core that face the N heating units with the N heating units. The heating includes switching operation of the N heating units from one to less than N at a time.