Laminated Iron Core Resin Filling Temperature Control
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Solution Overview
Problem
Existing methods for manufacturing laminated iron cores face issues where preheating may not consistently achieve a temperature suitable for resin filling, leading to potential solidification problems such as insufficient filling or excessive resin overflow, resulting in improper filling of resin materials.
Innovation Solution
A method and apparatus that involve preheating a laminated body, measuring its temperature, and only feeding it into a molding device if within a predetermined range, ensuring the resin filling holes are filled with resin materials at an optimal temperature, using a preheating device, temperature sensor, molding device, conveyor, and controller to control the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the laminated body is preheated before being filled with resin materials, then the temperature of the laminated body increases, but the temperature may become too low or too high leading to improper filling
Solution Approach 1:
The patent implements a feedback mechanism by measuring the temperature of the laminated body after preheating and using this measurement to determine whether to proceed with resin filling. The temperature measurement feedback allows the system to adjust the process accordingly, ensuring the temperature is within the appropriate range for proper resin filling, thus resolving the contradiction between achieving sufficient heating and maintaining precise filling quality.
Solution Approach 2:
The patent changes the parameter of temperature by implementing preheating and then measuring the actual temperature to determine the next process step. This parameter change approach allows the system to adapt the resin filling process based on the actual temperature state, ensuring optimal filling conditions and preventing both under-heating and over-heating issues.
2Reliability
If the temperature of the laminated body is too low, then the resin materials solidify rapidly, but if the temperature is too high, then the resin materials solidify slowly causing burrs
Solution Approach 1:
The temperature measurement and decision-making mechanism provides feedback control that prevents both rapid solidification (which causes insufficient filling) and slow solidification (which causes burrs). By measuring the temperature and only proceeding with resin filling when the temperature is within the predetermined appropriate range, the system ensures reliable solidification control and eliminates the harmful effects of both under-temperature and over-temperature conditions.
3Manufacturing precision
If preheating is performed to achieve suitable temperature for resin filling, then the filling quality improves, but the process complexity increases due to temperature control requirements
Solution Approach 1:
The patent uses a relatively simple feedback mechanism involving temperature measurement and a predetermined range check to ensure proper resin filling quality. This feedback approach achieves high manufacturing precision without requiring complex temperature control systems, as it relies on measurement and conditional process continuation rather than active real-time temperature adjustment.
Solution Approach 2:
The system allows the laminated body to self-regulate its temperature through preheating, and the temperature measurement serves as a passivity check rather than an active control mechanism. This self-service approach achieves good filling quality without requiring complex external temperature control systems, as the process relies on the material's own thermal properties and a simple go/no-go decision based on temperature measurement.
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 ensures that the laminated iron core is properly filled with resin materials, preventing issues like rapid solidification or excessive resin overflow by ensuring the temperature is within the suitable range for resin filling.
Implementation Method 1
preheating a laminated body in which a plurality of iron core pieces are laminated
Implementation Method 2
measuring a temperature of the laminated body after preheating the laminated body
Data Source
AI summary
A method for manufacturing a laminated iron core includes preheating a laminated body in which a plurality of iron core pieces are laminated and which includes a resin filling hole, measuring a temperature of the laminated body after preheating the laminated body, determining whether or not the temperature measured is within a predetermined range, feeding the laminated body into a molding device in a case where it is determined that the temperature is within the predetermined range, and filling the resin filling hole of the laminated body with a resin material in the molding device.