Laminated Iron Core Punching with Auxiliary Nullification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing laminated iron cores face challenges in achieving high accuracy and low cost due to alignment issues with punches, leading to potential displacement of protrusions during lamination and increased maintenance costs from punch damage.
Innovation Solution
A device and method utilizing a punch unit with a set of punches and auxiliary punches to form protrusions on a metal sheet, where the auxiliary punches perform nullification processing to enhance positional accuracy and reduce the need for replacing damaged punches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple punches are arranged in a line to form shaft holes at different angles, then the protruding portions can face different angles, but the punches may be misaligned causing displacement of protrusions during lamination
Solution Approach 1:
The punch set is divided into M functional punches that form protrusions and L auxiliary punches that perform nullification processing. This segmentation allows independent optimization of each punch's function, ensuring that the functional punches maintain high positional accuracy while auxiliary punches compensate for any misalignment through their nullification action.
Solution Approach 2:
The invention changes the operational parameters of the punch system by introducing auxiliary punches with different functionality. These auxiliary punches are configured to perform nullification processing, which effectively cancels out the effects of any misalignment that may occur during the punching process, thereby maintaining manufacturing precision despite the complexity of forming multiple angled protrusions.
2Device complexity
If one punch forms both the protruding portion and the opening portion of the shaft hole, then the structure is simplified, but the punch is prone to damage and requires frequent replacement
Solution Approach 1:
The punch system is segmented into functional punches for forming protrusions and auxiliary punches for nullification. This segmentation allows the functional punches to be optimized for their specific shaping task, reducing the complexity and stress on each individual punch, thereby improving reliability and reducing the frequency of replacement.
Solution Approach 2:
The invention extracts the nullification function from the primary punching operation and assigns it to separate auxiliary punches. This extraction allows the main functional punches to focus solely on forming the protrusions with their complex geometries, reducing their mechanical stress and susceptibility to damage, thus improving overall system reliability.
3Shape
If punches are used to form complex protrusion shapes, then the required geometry is achieved, but the punches are easily damaged due to the complicated shape
Solution Approach 1:
The punching operation is segmented into multiple specialized punches, each responsible for specific aspects of the protrusion formation. The functional punches are designed with simpler, more robust geometries optimized for their specific forming tasks, while auxiliary punches handle the nullification. This segmentation reduces the complexity of individual punches, making them more durable while still achieving the required complex overall protrusion shape.
Solution Approach 2:
The invention changes the operational parameters by distributing the forming tasks across multiple punches with different functions. This allows each punch to operate within optimized parameter ranges that enhance durability, while the cumulative effect of multiple punches achieves the complex required geometry without over-stressing any single punch.
Data Source
AI summary
A device for manufacturing a laminated iron core includes: a punch unit configured to form protrusions, and including N number of punches as a set, the N being a natural number larger than M; and N number of auxiliary punches. The N number of auxiliary punches are configured such that L number of auxiliary punches selected from the N number of auxiliary punches performs a nullification processing on a metal sheet, the nullification processing being configured to nullify a processing with the L number of punches among the N number of punches, the L being the natural number that is obtained by subtracting the M from the N. According to the above configurations, for example, since a processing position with the plurality of punches is limited in one position, a positional accuracy of protrusions formed in punched members with the plurality of punches is improved.