Rotational Lamination of Iron Cores at Shape-Change Boundaries
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Solution Overview
Problem
In manufacturing laminated iron cores, plate thickness deviations and shape changes due to non-uniform metal sheet thicknesses lead to inconsistent lamination thickness and mechanical weaknesses, such as cracks and gaps, particularly at design change portions.
Innovation Solution
A manufacturing method involving rotational lamination, where punched members with different shapes are laminated with synchronized rotational angles at design change portions to maintain consistent lamination thickness and mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If iron core pieces are simply laminated without adjusting rotational angle, then manufacturing process is simple, but lamination thickness cannot be controlled within tolerance due to plate thickness deviation
Solution Approach 1:
The rotational lamination angle is adjusted in advance before lamination occurs. By pre-setting the rotational angle based on the type of punched member, the method compensates for plate thickness deviations before they affect the final lamination thickness, ensuring consistent thickness within tolerance.
Solution Approach 2:
Different rotational lamination angles are applied to different types of punched members (first type vs second type). This local differentiation allows the process to account for shape variations in specific regions, maintaining uniform lamination thickness across the entire laminated body despite variations in individual plate characteristics.
2Productivity
If punched members with different shapes are continuously laminated, then productivity is improved, but shape changes and plate thickness deviations cause cracks and gaps
Solution Approach 1:
The rotational lamination angle is determined in advance based on the punched member type before the lamination process begins. This preliminary angle setting prevents misalignment and structural defects that would otherwise occur during continuous lamination of differently shaped members, maintaining both productivity and reliability.
Solution Approach 2:
The rotational lamination angle parameter is changed according to the type of punched member being laminated. By adjusting this angular parameter based on member shape variations, the process maintains proper alignment and structural integrity even when continuously laminating members with different shapes.
3Manufacturing precision
If rotational lamination angle is changed for each punched member, then lamination thickness consistency is improved, but control complexity increases
Solution Approach 1:
Punched members are segmented into different types (first type and second type) based on their shapes. This segmentation allows the control system to apply simplified angle rules rather than managing continuous variable adjustments, reducing control complexity while maintaining precision.
Solution Approach 2:
Different rotational angles are assigned to different types of punched members based on their local characteristics. This approach allows precise control of lamination thickness for each member type without requiring a complex system that calculates angles for every individual member, simplifying the overall control architecture.
Data Source
AI summary
A manufacturing method for a laminated iron core, the manufacturing method includes: a punching process of punching a metal sheet to form a plurality of punched members including a first punched member and a second punched member; and a laminating process of forming a laminated body by laminating the plurality of punched members while changing a rotational lamination angle each time one or more punched members are laminated. In the laminating process, the plurality of punched members are laminated such that the rotational lamination angle is the same between the first punched member and the second punched member adjacent to each other in a boundary portion between two or more of the first punched members that are continuously laminated and two or more of the second punched members that are continuously laminated.