Laminated Iron Core Stacking Using Multi-Point Thickness Averaging
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Solution Overview
Problem
The existing methods for manufacturing laminated iron cores face challenges in achieving consistent lamination thickness due to variations in the thickness of iron core pieces punched from a workpiece, leading to errors in the calculated lamination thickness of the laminated iron core.
Innovation Solution
A method involving the measurement of iron core piece thickness at multiple points along the conveying direction of the workpiece, calculating an average thickness for each piece, and adjusting the number of stacked pieces to accumulate a target lamination thickness, thereby reducing thickness deviations and achieving accurate lamination thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the thickness is measured at only one location in each designated portion, then the measurement process is simple, but there may be a significant error between the calculated lamination thickness and the actual lamination thickness
Solution Approach 1:
The patent divides the thickness measurement into multiple segments (multiple measurement points) along the conveying direction of the workpiece. Instead of measuring at a single location, the measurement is segmented into multiple points, and the average of these measurements is used to represent the thickness of the entire designated portion, thereby reducing measurement error.
Solution Approach 2:
The patent performs preliminary measurement actions by measuring the thickness at multiple points before calculating the average thickness. This preliminary multi-point measurement ensures that thickness variations within the designated portion are captured, and the average value is computed in advance to be used for lamination thickness calculation.
2Manufacturing precision
If the number of stacked iron core pieces is set to be constant, then the stacking process is simple, but a laminated iron core having a desired thickness may not be manufactured due to thickness variations in iron core pieces
Solution Approach 1:
The patent makes the number of stacked iron core pieces dynamic rather than constant. The stacking number is adjusted based on the calculated average thickness of each iron core piece, allowing the stacking process to adapt to thickness variations and achieve the desired lamination thickness.
Solution Approach 2:
The patent implements a feedback mechanism where the measured thickness of each iron core piece is used to determine the number of pieces to be stacked. The thickness measurement feeds back into the stacking decision, ensuring that the final lamination thickness meets the desired specification.
3Manufacturing precision
If multiple measurement points are used to measure the thickness, then the lamination thickness accuracy is improved, but the measurement time and process complexity increase
Solution Approach 1:
The patent maintains continuous useful action during measurement by taking multiple thickness measurements in sequence along the conveying direction without interrupting the overall process flow. The measurements are taken continuously as the workpiece moves, and the average is computed efficiently, minimizing time loss while improving accuracy.
Data Source
AI summary
A method for manufacturing a laminated iron core includes forming a laminated body by punching out iron core pieces from a plate-shaped workpiece that is intermittently conveyed, measuring, at multiple measurement points arranged in a conveying direction of the workpiece, a thickness of a designated portion of the workpiece from which each iron core piece is to be punched out, calculating, as an average thickness of each iron core piece, an average value of measured values at the multiple measurement points, and calculating a lamination thickness of the laminated body by accumulating the average thicknesses of the iron core pieces.