Laminated Iron Core Manufacturing via Rotational Stacking
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Solution Overview
Problem
The existing method for manufacturing laminated iron cores requires a large-sized press apparatus and complex mechanical configurations due to dedicated stations for processing two kinds of annular iron core piece rows, leading to increased costs and complexity in control and equipment requirements.
Innovation Solution
A method that laminates annular iron core piece rows with yokes and teeth, where adjacent pieces have different shapes, allowing for the formation of uneven parts on the circumferential ends, enabling the manufacturing of laminated iron cores in a single press step by changing the rotational angle of newly laminated rows relative to the lastly laminated ones, thus eliminating the need for separate stations and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated stations are used for processing two kinds of annular iron core piece rows, then the manufacturing precision and reliability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the processing of two different kinds of annular iron core piece rows into a single integrated press apparatus. Instead of using separate dedicated stations for each type, the invention uses one press apparatus with a die unit that can process both types alternately, thereby reducing device complexity while maintaining manufacturing reliability through controlled alternating processing
Solution Approach 2:
The patent prepares both kinds of annular iron core piece rows in advance with pre-designed uneven parts at their circumferential ends. This preliminary preparation allows the pieces to be automatically identified and processed in the correct sequence without requiring complex real-time decision-making mechanisms, thus simplifying the mechanical configuration while ensuring reliable assembly
2Manufacturing precision
If dedicated stations are used for processing two kinds of annular iron core piece rows, then the manufacturing precision is improved, but the control complexity increases
Solution Approach 1:
The patent incorporates uneven parts at the circumferential ends of the iron core pieces during the initial manufacturing stage. These pre-formed features serve as physical identifiers that guide the automatic stacking process, eliminating the need for complex control systems to identify and sort pieces, thereby maintaining manufacturing precision while reducing control complexity
Solution Approach 2:
The uneven parts on the iron core pieces enable the stacking process to be self-guiding. When pieces are placed in the die unit, the uneven parts naturally orient the pieces and indicate their correct position in the stacking sequence, allowing the system to self-regulate without complex external control mechanisms
3Reliability
If separate stations are used for each annular iron core piece row, then the manufacturing reliability is improved, but the equipment cost increases
Solution Approach 1:
The patent merges the functionality of multiple dedicated press stations into a single press apparatus with an integrated die unit. This consolidation reduces equipment investment while maintaining reliability through the use of pre-designed uneven parts that ensure correct stacking sequences without requiring separate processing stations for each iron core piece row type
Solution Approach 2:
The die unit in the patent is designed with universal functionality to process both kinds of annular iron core piece rows. By making the press apparatus multi-functional rather than dedicated to a single type, the invention reduces equipment cost while maintaining the ability to reliably manufacture different types of iron core pieces with consistent quality
4Manufacturing precision
If multiple dedicated stations are used, then the manufacturing precision is improved, but the press apparatus size increases
Solution Approach 1:
The patent combines multiple processing stations into a single integrated press apparatus with a unified die unit. This consolidation reduces the overall footprint and size of the equipment while maintaining lamination precision through the use of pre-designed uneven parts that guide correct piece placement and stacking sequences within the compact apparatus
Data Source
AI summary
A method for manufacturing a laminated iron core includes providing a plurality of annular iron core piece rows, each of which is configured by annularly arranging a plurality of divided iron core pieces including yokes and teeth, and the yokes of the annularly-adjacent divided iron core pieces in the annular iron core piece row are mutually different in shape. In the method, the annular iron core piece rows are laminated by changing a rotational angle of the newly laminated annular iron core piece row relatively to the lastly laminated annular iron core piece row laminated so that the divided iron core piece with a shape different from that of the divided iron core piece is laminated on the lastly laminated divided iron core piece.