Laminar Article Fastener Nesting for Electrical Machines
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Solution Overview
Problem
Traditional laminar structures for electrical machines suffer from air spaces between laminations, leading to incorrect coupling, mechanical and dimensional issues, and 'springy' effects, especially with large rotations and tall structures, where maintaining correct spiraling and compensation is challenging.
Innovation Solution
A laminar article design where first laminations have projecting fasteners and recesses on one surface, and second laminations have through apertures for the fasteners to pass through, allowing direct contact and eliminating air spaces, with the height of fasteners independent of lamination thickness, and incorporating anti-rotation elements to prevent deformation and ensure accurate spiraling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners are inserted into seats of adjacent laminations, then laminations are fixed together, but air spaces remain between laminations causing incorrect coupling and springy effects
Solution Approach 1:
The lamination stack is segmented into two types of laminations: first laminations with fasteners and recesses, and second laminations with through apertures. This segmentation allows different coupling mechanisms to be applied to different laminations, eliminating air spaces while maintaining structural integrity.
Solution Approach 2:
The fasteners of first laminations are nested through the through apertures of second laminations, creating a interlocked structure where fasteners pass completely through alternating laminations. This nesting eliminates gaps and ensures direct contact between all laminations.
2Manufacturing precision
If fastener height is related to lamination thickness to ensure correct connection, then connection accuracy is improved, but manufacturing complexity increases for tall structures
Solution Approach 1:
The fasteners are designed with universal dimensions that are independent of lamination thickness. The same fastener can be used across laminations of varying thicknesses, simplifying manufacturing for tall structures while maintaining connection accuracy through the through-aperture mechanism.
3Device complexity
If traditional systems are used for lamination fixation, then simple structure is maintained, but correct spiraling and compensation cannot be achieved for large rotations
Solution Approach 1:
The through apertures in second laminations act as intermediaries that guide and constrain the fasteners, enabling precise spiraling and compensation. This intermediary structure allows large rotations (up to 180°) while maintaining correct spiraling angles, which traditional direct fastener-to-seat connections cannot achieve.
4Ease of manufacture
If laminations are directly superposed without through apertures, then manufacturing is simpler, but air spaces cause electrical and mechanical issues
Solution Approach 1:
The through apertures are pre-formed in second laminations before assembly, and fasteners are designed to pass through these apertures during assembly. This preliminary preparation ensures direct lamination contact and eliminates air spaces without significantly complicating the manufacturing process.
Data Source
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AI summary
The laminar article (1) for electrical use comprises a plurality of superposed first metal laminations (2) fixed together. Each of the first laminations (2) is provided with at least one fastener (3, 3a, 3b) projecting from a first surface (4) thereof and defining a recess (5, 5b) in its opposite side. Each fastener (3, 3a, 3b) of one lamination (2) is arranged to fit into a recess (5, 5b) of an adjacent lamination. The article presents second laminations (9) interposed between at least two adjacent first laminations (2) fixed together. The second laminations (9) are provided with through apertures (10) which are traversed by the fasteners (3, 3a, 3b) which fix the adjacent first laminations together. The method consists of die-cutting a plurality of laminations from a metal sheet, rotating the die-cut laminations and superposing them, to then fix them together in predetermined manner. The laminations can be die-cut with a reference axis thereof rotated through a predetermined angle about a reference axis of the metal sheet, to limit the rotations to be imposed on the laminations during their mutual fixing.