Laminated Iron Core Manufacturing with Rotating Re-lamination
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Solution Overview
Problem
The existing methods for manufacturing laminated iron cores require manual handling and separation of block iron cores, leading to potential mistakes in the order of lamination or rotation angle, resulting in defective products, and additional steps like burr removal are inefficient due to the need for disassembly.
Innovation Solution
A method and apparatus that include a block iron core separating unit, a rotating and laminating unit, and inspection units to individually separate and re-laminate block iron cores in a different order, using a disk-shaped placement table for efficient arrangement and inspection, preventing mistakes and allowing parallel processing of tasks like burr removal and thickness inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling and separation of block iron cores is used, then flexibility in inspection and processing is improved, but mistakes in lamination order and rotation angle occur leading to defective products
Solution Approach 1:
The patent replaces manual mechanical handling with an automated rotating and laminating apparatus that mechanically separates and re-laminates block iron cores with precise control. The apparatus includes a rotating table with multiple stations that automatically perform separation, inspection, and re-lamination operations, eliminating human error in determining lamination order and rotation angles.
Solution Approach 2:
The system performs self-inspection and self-correction by automatically detecting the lamination thickness and rotation angle of each block iron core, then autonomously adjusting the re-lamination process to ensure accuracy. The apparatus includes sensors and control systems that monitor and regulate the processing parameters without human intervention.
2Measurement precision
If block iron cores are separated for inspection, then lamination thickness can be verified, but additional time is required for disassembly and reassembly
Solution Approach 1:
The patent implements continuous processing by arranging inspection, separation, and re-lamination operations in a circular flow on a rotating table. Multiple workstations operate simultaneously at different positions on the rotating table, allowing one block iron core to be inspected while another is being processed, eliminating idle time and maintaining continuous productive action throughout the system.
Solution Approach 2:
The system performs preliminary separation and positioning of block iron cores before inspection, so that when inspection is complete, the cores are already prepared for immediate re-lamination. The rotating table pre-arranges the separated cores in the correct sequence and orientation, eliminating the need for time-consuming repositioning after inspection.
3Manufacturing precision
If multiple tasks are performed sequentially, then each task can be completed thoroughly, but overall productivity is reduced
Solution Approach 1:
The patent transitions from sequential one-dimensional processing to parallel multi-dimensional processing by arranging multiple workstations around a rotating table in a circular layout. This spatial arrangement allows simultaneous execution of separation, inspection, burr removal, and re-lamination operations on different block iron cores at the same time, multiplying productivity while maintaining quality through dedicated stations for each task.
Data Source
AI summary
There is provided a method for manufacturing a laminated iron core. The method includes receiving a plurality of block iron cores which are temporarily laminated and ejected from a die, each block iron core being formed by laminating a plurality of iron core pieces that are blanked from a thin plate workpiece using the die, individually separating the temporarily laminated block iron cores by a block iron core separating unit, and rotating and laminating each of the separated block iron cores by a rotating and laminating unit in order different from order of lamination of the temporarily laminated block iron cores before separation in a place different from a location of the die.